Phillips Disaster
Encyclopedia
The Phillips Disaster refers to a devastating series of explosion
s and fire on October 23, 1989 near the Houston Ship Channel
in Pasadena
, Texas
, USA. The initial blast registered 3.5 on the Richter Scale, and the conflagration
took 10 hours to bring under control. Some 23 employees were killed and 314 were injured.
material used to make milk bottles and other containers. The Houston Chemical Complex (HCC) facility employed 905 company employees and approximately 600 daily contract employees, who were engaged primarily in regular maintenance activities and new plant construction.
77506. A massive and devastating explosion and fire ripped through the Phillips 66
Company's Houston Chemical Complex (HCC), killing 23 persons—all working at the facility—and injuring 314 others (185 Phillips 66
employees and 129 contract employees). In addition to the loss of life and injuries, the explosion affected all facilities within the complex, causing $715.5 million worth of damage plus an additional business disruption loss estimated at $700 million. The two polyethylene production plants
nearest the source of the blast were destroyed, and in the HCC administration building nearly 0.5 mile away, windows were shattered and bricks ripped out. The initial explosion was equivalent to an earthquake registering 3.5 on the Richter Scale and threw debris as far away as six miles.
The accident resulted from a release of extremely flammable process
gases that occurred during regular maintenance operations on one of the plant's polyethylene reactors
. More than 85,000 pounds of highly flammable gases were released through an open valve
. A vapor cloud formed and traveled rapidly through the polyethylene plant. Within 90 to 120 seconds, the vapor cloud came into contact with an ignition source and exploded with the force of 2.4 tons of TNT.
The initial response was provided by the Phillips 66
Company fire brigade which was soon joined by members of the Channel Industries Mutual Aid association (CIMA). Cooperating governmental agencies were the Texas Air Control Board, the Harris County Pollution Control Board, the Federal Aviation Administration
(FAA), the U.S. Coast Guard, the Occupational Safety and Health Administration
(OSHA) and the U.S. Environmental Protection Agency (EPA).
. The fire was brought under control within about 10 hours as a result of the combined efforts of fire brigades from other nearby companies, local fire department
s, and the Phillips 66
foam trucks and fire brigade.
(Texas) Medical Examiner
and County Coroner
. Search and rescue efforts were delayed until the fire and heat subsided and all danger of further explosions had passed. These operations were difficult because of the extensive devastation in the HCC and the danger of structural collapse on the search and rescue team. The Phillips 66
Company requested, and the FAA approved and implemented, a 1-mile no-fly zone around the plant to prevent engine vibration and/or helicopter rotor downwash from dislodging any of the wreckage. The U.S. Coast Guard and City of Houston fire boats evacuated to safety over 100 trapped people across the Houston Ship Channel
. OSHA preserved evidence for evaluation regarding the cause of the catastrophe.
Phillips employees fatally wounded, listed by name, age, city of residence within Texas
A granite memorial (at 29°43′59.4"N 95°10′57"W near 924 Jefferson Rd, Pasadena, TX 77506, USA) was dedicated on the first anniversary of the disaster, and was declared by company officials to remain open at all times to the general public.
; inadequate standard operating procedures (SOPs); non-fail-safe block valve; inadequate maintenance permitting system; inadequate lockout/tagout procedures; lack of combustible gas detection and alarm system; presence of ignition sources; inadequate ventilation systems for nearby buildings; fire protection
system not maintained in an adequate state of readiness. Additional factors found by OSHA included: Proximity of high-occupancy structures (control rooms) to hazardous operations; inadequate separation between buildings; crowded process equipment; insufficient separation between the reactors and the control room for emergency shutdown procedures.
Quoting from a key OSHA document:
Company, OSHA agreed to delete the willful characterization of the citations and Phillips 66
agreed to pay a $4 million fine and to institute process safety management procedures at HCC and the company's sister facilities at Sweeny, Texas
; Borger, Texas
; and Woods Cross, Utah
.
Today, the facility continues to manufacture high-density polyethylene (HDPE), as well as K-Resin SBC. This complex employs 750 workers for the production of specialty chemicals, including 150 operations and maintenance personnel.
The facility experienced additional fatalities in 1999
and 2000
. A massive propane
leak
occurred on 25-Jun-2008 in a utility easement just outside plant property.
Explosion
An explosion is a rapid increase in volume and release of energy in an extreme manner, usually with the generation of high temperatures and the release of gases. An explosion creates a shock wave. If the shock wave is a supersonic detonation, then the source of the blast is called a "high explosive"...
s and fire on October 23, 1989 near the Houston Ship Channel
Houston Ship Channel
The Houston Ship Channel, located in Houston, Texas, is part of the Port of Houston—one of the United States's busiest seaports. The channel is the conduit for ocean-going vessels between the Houston-area shipyards and the Gulf of Mexico.-Overview:...
in Pasadena
Pasadena, Texas
Pasadena is a city in the U.S. state of Texas within the metropolitan area. It is the second-largest city in Harris County, 17th-largest in Texas, and 162nd largest in the United States. The area was founded in 1893 by John H. Burnett of Galveston....
, Texas
Texas
Texas is the second largest U.S. state by both area and population, and the largest state by area in the contiguous United States.The name, based on the Caddo word "Tejas" meaning "friends" or "allies", was applied by the Spanish to the Caddo themselves and to the region of their settlement in...
, USA. The initial blast registered 3.5 on the Richter Scale, and the conflagration
Conflagration
A conflagration or a blaze is an uncontrolled burning that threatens human life, health, or property. A conflagration can be accidentally begun, naturally caused , or intentionally created . Arson can be accomplished for the purpose of sabotage or diversion, and also can be the consequence of...
took 10 hours to bring under control. Some 23 employees were killed and 314 were injured.
Prior to the disaster
The facility produced approximately 1.5 billion pounds per year of high-density polyethylene (HDPE), a plasticPlastic
A plastic material is any of a wide range of synthetic or semi-synthetic organic solids used in the manufacture of industrial products. Plastics are typically polymers of high molecular mass, and may contain other substances to improve performance and/or reduce production costs...
material used to make milk bottles and other containers. The Houston Chemical Complex (HCC) facility employed 905 company employees and approximately 600 daily contract employees, who were engaged primarily in regular maintenance activities and new plant construction.
The explosions
The incident started at approximately 1:00 PM local time on October 23, 1989, at 1400 Jefferson Road, Pasadena, TexasPasadena, Texas
Pasadena is a city in the U.S. state of Texas within the metropolitan area. It is the second-largest city in Harris County, 17th-largest in Texas, and 162nd largest in the United States. The area was founded in 1893 by John H. Burnett of Galveston....
77506. A massive and devastating explosion and fire ripped through the Phillips 66
Phillips 66
Phillips 66 is a brand of gasoline and service station in the U.S. It is owned by the ConocoPhillips Company.Phillips 66 will also be the name of the future downstream company created when ConocoPhillips repositions its integrated assets and businesses into two independent, publicly-traded...
Company's Houston Chemical Complex (HCC), killing 23 persons—all working at the facility—and injuring 314 others (185 Phillips 66
Phillips 66
Phillips 66 is a brand of gasoline and service station in the U.S. It is owned by the ConocoPhillips Company.Phillips 66 will also be the name of the future downstream company created when ConocoPhillips repositions its integrated assets and businesses into two independent, publicly-traded...
employees and 129 contract employees). In addition to the loss of life and injuries, the explosion affected all facilities within the complex, causing $715.5 million worth of damage plus an additional business disruption loss estimated at $700 million. The two polyethylene production plants
Chemical plant
A chemical plant is an industrial process plant that manufactures chemicals, usually on a large scale. The general objective of a chemical plant is to create new material wealth via the chemical or biological transformation and or separation of materials. Chemical plants use special equipment,...
nearest the source of the blast were destroyed, and in the HCC administration building nearly 0.5 mile away, windows were shattered and bricks ripped out. The initial explosion was equivalent to an earthquake registering 3.5 on the Richter Scale and threw debris as far away as six miles.
The accident resulted from a release of extremely flammable process
Chemical process
In a "scientific" sense, a chemical process is a method or means of somehow changing one or more chemicals or chemical compounds. Such a chemical process can occur by itself or be caused by somebody. Such a chemical process commonly involves a chemical reaction of some sort...
gases that occurred during regular maintenance operations on one of the plant's polyethylene reactors
Chemical reactor
In chemical engineering, chemical reactors are vessels designed to contain chemical reactions. The design of a chemical reactor deals with multiple aspects of chemical engineering. Chemical engineers design reactors to maximize net present value for the given reaction...
. More than 85,000 pounds of highly flammable gases were released through an open valve
Valve
A valve is a device that regulates, directs or controls the flow of a fluid by opening, closing, or partially obstructing various passageways. Valves are technically pipe fittings, but are usually discussed as a separate category...
. A vapor cloud formed and traveled rapidly through the polyethylene plant. Within 90 to 120 seconds, the vapor cloud came into contact with an ignition source and exploded with the force of 2.4 tons of TNT.
Early response
Phillips 66
Phillips 66 is a brand of gasoline and service station in the U.S. It is owned by the ConocoPhillips Company.Phillips 66 will also be the name of the future downstream company created when ConocoPhillips repositions its integrated assets and businesses into two independent, publicly-traded...
Company fire brigade which was soon joined by members of the Channel Industries Mutual Aid association (CIMA). Cooperating governmental agencies were the Texas Air Control Board, the Harris County Pollution Control Board, the Federal Aviation Administration
Federal Aviation Administration
The Federal Aviation Administration is the national aviation authority of the United States. An agency of the United States Department of Transportation, it has authority to regulate and oversee all aspects of civil aviation in the U.S...
(FAA), the U.S. Coast Guard, the Occupational Safety and Health Administration
Occupational Safety and Health Administration
The United States Occupational Safety and Health Administration is an agency of the United States Department of Labor. It was created by Congress of the United States under the Occupational Safety and Health Act, signed by President Richard M. Nixon, on December 29, 1970...
(OSHA) and the U.S. Environmental Protection Agency (EPA).
Firefighting
The fire-fighting water system at the HCC was part of the process water system. When the first explosion occurred, some fire hydrants were sheared off at ground level by the blast. The result was inadequate water pressure for fire fighting. The shut-off valves which could have been used to prevent the loss of water from ruptured lines in the plant were out of reach in the burning wreckage. No remotely-operated fail-safe isolation valves existed in the combined plant/fire-fighting water system. In addition, the regular-service fire-water pumps were disabled by the fire which destroyed their electrical power cables. Of the three backup diesel-operated fire pumps, one had been taken out of service, and one ran out of fuel in about an hour. Fire-fighting water was brought in by hoses laid to remote sources: settling ponds, a cooling tower, a water main at a neighboring plant, and even the Houston Ship ChannelHouston Ship Channel
The Houston Ship Channel, located in Houston, Texas, is part of the Port of Houston—one of the United States's busiest seaports. The channel is the conduit for ocean-going vessels between the Houston-area shipyards and the Gulf of Mexico.-Overview:...
. The fire was brought under control within about 10 hours as a result of the combined efforts of fire brigades from other nearby companies, local fire department
Fire department
A fire department or fire brigade is a public or private organization that provides fire protection for a certain jurisdiction, which typically is a municipality, county, or fire protection district...
s, and the Phillips 66
Phillips 66
Phillips 66 is a brand of gasoline and service station in the U.S. It is owned by the ConocoPhillips Company.Phillips 66 will also be the name of the future downstream company created when ConocoPhillips repositions its integrated assets and businesses into two independent, publicly-traded...
foam trucks and fire brigade.
Search and rescue
All search and rescue operations were coordinated by the Harris CountyHarris County, Texas
As of the 2010 Census, the population of the county was 4,092,459, White Americans made up 56.6% of Harris County's population; non-Hispanic whites represented 33.0% of the population. Black Americans made up 18.9% of the population. Native Americans made up 0.7% of Harris County's population...
(Texas) Medical Examiner
Medical examiner
A medical examiner is a medically qualified government officer whose duty is to investigate deaths and injuries that occur under unusual or suspicious circumstances, to perform post-mortem examinations, and in some jurisdictions to initiate inquests....
and County Coroner
Coroner
A coroner is a government official who* Investigates human deaths* Determines cause of death* Issues death certificates* Maintains death records* Responds to deaths in mass disasters* Identifies unknown dead* Other functions depending on local laws...
. Search and rescue efforts were delayed until the fire and heat subsided and all danger of further explosions had passed. These operations were difficult because of the extensive devastation in the HCC and the danger of structural collapse on the search and rescue team. The Phillips 66
Phillips 66
Phillips 66 is a brand of gasoline and service station in the U.S. It is owned by the ConocoPhillips Company.Phillips 66 will also be the name of the future downstream company created when ConocoPhillips repositions its integrated assets and businesses into two independent, publicly-traded...
Company requested, and the FAA approved and implemented, a 1-mile no-fly zone around the plant to prevent engine vibration and/or helicopter rotor downwash from dislodging any of the wreckage. The U.S. Coast Guard and City of Houston fire boats evacuated to safety over 100 trapped people across the Houston Ship Channel
Houston Ship Channel
The Houston Ship Channel, located in Houston, Texas, is part of the Port of Houston—one of the United States's busiest seaports. The channel is the conduit for ocean-going vessels between the Houston-area shipyards and the Gulf of Mexico.-Overview:...
. OSHA preserved evidence for evaluation regarding the cause of the catastrophe.
List of fatalities
Phillips employees fatally wounded, listed by name, age, city of residence within TexasTexasTexas is the second largest U.S. state by both area and population, and the largest state by area in the contiguous United States.The name, based on the Caddo word "Tejas" meaning "friends" or "allies", was applied by the Spanish to the Caddo themselves and to the region of their settlement in...
, and official date of death (following recovery and identification of remains or eventual death from injuries):
- Stephen Donald Huff, 21, 25-Oct-1989
- Ruben Quilantan Alamillo, 35, HoustonHouston, TexasHouston is the fourth-largest city in the United States, and the largest city in the state of Texas. According to the 2010 U.S. Census, the city had a population of 2.1 million people within an area of . Houston is the seat of Harris County and the economic center of , which is the ...
, 25-Oct-1989 - James Edward Allen, 38, PasadenaPasadena, TexasPasadena is a city in the U.S. state of Texas within the metropolitan area. It is the second-largest city in Harris County, 17th-largest in Texas, and 162nd largest in the United States. The area was founded in 1893 by John H. Burnett of Galveston....
, 02-Nov-1989 - Albert Elroy Arce, 35, Deer ParkDeer Park, TexasDeer Park is a city in the U.S. state of Texas within the Houston–Sugar Land–Baytown metropolitan area. The city is located in Harris County and is situated in Southeast Texas. As of the 2010 U.S. Census, the population of Deer Park was 32,010....
, 28-Oct-1989 (listed as Eloy Albert Arce) - James Henry Campbell, Jr., 30, BaytownBaytown, TexasBaytown is a city within Harris County and partially in Chambers County in the Gulf Coast region of the U.S. state of Texas. Located within the Houston–Sugar Land–Baytown metropolitan area, it lies along both State Highway 146 and Interstate 10. As of 2010, Baytown had an population of 71,802...
, 26-Oct-1989 - Eloy Gonzales, 36, Houston, 01-Nov-1989
- Mark Lloyd Greeson, 30, Pasadena, 28-Oct-1989
- Jeffrey Lester Harrison, 36, Houston, 24-Oct-1989
- Delbert Lynn Haskell, 43, Deer Park, 29-Oct-1989
- Scotty Dale Hawkins, 32, Houston, 28-Oct-1989
- James Deowens Hubbard, 45, Houston, 25-Oct-1989 (listed as James Hubbard, Jr.)
- Richard Leos, 30, La PorteLa Porte, TexasLa Porte is a city in Harris County, Texas within the Bay Area of the Houston–Sugar Land–Baytown metropolitan area. As of the 2000 U.S. Census, the city population was 31,880...
, 29-Oct-1989 - James Arthur Nichols, 40, Baytown, 27-Oct-1989
- Jesse Thomas Northrup, 43, BrookshireBrookshire, TexasBrookshire is a city 34 miles west of downtown Houston along Interstate 10, 7 miles west of Katy, the fastest growing residential region in the U.S.. Brookshire is part of the Interstate 10 Energy Corridor, part of the west Houston and Katy Market, and a member of West I-10 Chamber of Commerce. ...
, 28-Oct-1989 - Mary Kathryn O'Connor, 34, Houston, 29-Oct-1989
- Gerald Galen Pipher, 39, Deer Park, 30-Oct-1989
- Cipriano Rodriguez, Jr., 42, Pasadena, 27-Oct-1989
- Jesse Oscar Trevino, 33, PearlandPearland, TexasPearland , is a city located along the Gulf Coast region in the US state of Texas within the metropolitan area and is in the counties of Brazoria, Fort Bend, and Harris. As of the census of 2000, the city's population was 37,640. As of 2008, Pearland is estimated to have a population of 90,700...
, 30-Oct-1989 - Lino Ralph Trujillo, 39, Pasadena, 29-Oct-1989
- Nathan Gene Warner, 30, Deer Park, 24-Oct-1989
Fish Engineering employees fatally wounded and official dates of death
- Juan Manuel Garcia, 30-Oct-1989
- Jose Lara Gonzalez, 23-Oct-1989
- William Scott Martin, 25-Oct-1989
- John Medrano, 30-Oct-1989 (listed as Juan Trejo-Medrano)
A granite memorial (at 29°43′59.4"N 95°10′57"W near 924 Jefferson Rd, Pasadena, TX 77506, USA) was dedicated on the first anniversary of the disaster, and was declared by company officials to remain open at all times to the general public.
OSHA findings
OSHA's major findings included: Lack of process hazard analysisProcess Hazard Analysis
Process Hazard Analysis is a set of organized and systematic assessments of the potential hazards associated with an industrial process. A PHA provides information intended to assist managers and employees in making decisions for improving safety and reducing the consequences of unwanted or...
; inadequate standard operating procedures (SOPs); non-fail-safe block valve; inadequate maintenance permitting system; inadequate lockout/tagout procedures; lack of combustible gas detection and alarm system; presence of ignition sources; inadequate ventilation systems for nearby buildings; fire protection
Fire protection
Fire protection is the study and practice of mitigating the unwanted effects of fires. It involves the study of the behaviour, compartmentalisation, suppression and investigation of fire and its related emergencies, as well as the research and development, production, testing and application of...
system not maintained in an adequate state of readiness. Additional factors found by OSHA included: Proximity of high-occupancy structures (control rooms) to hazardous operations; inadequate separation between buildings; crowded process equipment; insufficient separation between the reactors and the control room for emergency shutdown procedures.
Quoting from a key OSHA document:
"At the conclusion of the investigation (April 19, 1990), OSHA issued 566 willfulWillful violationIn the North American legal justice system system and in US Occupational Safety and Health regulations,willful violation is an "act done voluntarily with either...
and 9 serious violations with a combined total proposed penalty of $5,666,200 to Phillips 66Phillips 66Phillips 66 is a brand of gasoline and service station in the U.S. It is owned by the ConocoPhillips Company.Phillips 66 will also be the name of the future downstream company created when ConocoPhillips repositions its integrated assets and businesses into two independent, publicly-traded...
Company and 181 willfulWillful violationIn the North American legal justice system system and in US Occupational Safety and Health regulations,willful violation is an "act done voluntarily with either...
and 12 serious violations with a combined total proposed penalty of $729,600 to Fish Engineering and Construction, Inc., a maintenance contractor on the site."
OSHA citations
As a result of a settlement between OSHA and Phillips 66Phillips 66
Phillips 66 is a brand of gasoline and service station in the U.S. It is owned by the ConocoPhillips Company.Phillips 66 will also be the name of the future downstream company created when ConocoPhillips repositions its integrated assets and businesses into two independent, publicly-traded...
Company, OSHA agreed to delete the willful characterization of the citations and Phillips 66
Phillips 66
Phillips 66 is a brand of gasoline and service station in the U.S. It is owned by the ConocoPhillips Company.Phillips 66 will also be the name of the future downstream company created when ConocoPhillips repositions its integrated assets and businesses into two independent, publicly-traded...
agreed to pay a $4 million fine and to institute process safety management procedures at HCC and the company's sister facilities at Sweeny, Texas
Sweeny, Texas
Sweeny is a city in Brazoria County, Texas, USA. The population was 3,624 at the 2000 census, 7,316 if you include unincorporated areas of Sweeny. The city's motto is "A City With Pride", and is the westernmost incorporated town in the county.-Demographics:...
; Borger, Texas
Borger, Texas
Borger is the largest city in Hutchinson County, Texas, United States. The population was 14,302 at the 2000 census. Borger is named for businessman Asa Philip "Ace" Borger, who also established the Hutchinson County seat of Stinnett and several other small towns in Texas and Oklahoma.- History...
; and Woods Cross, Utah
Woods Cross, Utah
Woods Cross is a city in Davis County, Utah, United States. It is part of the Ogden–Clearfield, Utah Metropolitan Statistical Area. The population was 9,761 as of the 2010 census...
.
Facility today
The facility experienced additional fatalities in 1999
Phillips explosion of 1999
Two contractors were killed and three men were injured in an explosion on the morning of Wednesday, June 23, 1999, at Phillips Petroleum Company's K-Resin plant in its chemical complex at 1400 Jefferson Road, Pasadena, Texas 77506. An alarm sounded at 11:30 am when the blast occurred and a fire...
and 2000
Phillips explosion of 2000
At approximately 1:22 p.m. CT on March 27, 2000, an explosion and fire responsible for one death and 71 injuries occurred at Phillips Petroleum's Houston Chemical Complex at 1400 Jefferson Road, Pasadena, Texas 77506...
. A massive propane
Propane
Propane is a three-carbon alkane with the molecular formula , normally a gas, but compressible to a transportable liquid. A by-product of natural gas processing and petroleum refining, it is commonly used as a fuel for engines, oxy-gas torches, barbecues, portable stoves, and residential central...
leak
Leak
A leak is a hole or other opening, usually unintended and therefore undesired, in a container or fluid-containing system, such as a tank or a ship's hull, through which the contents of the container can escape or outside matter can enter the container...
occurred on 25-Jun-2008 in a utility easement just outside plant property.
See also
- Chevron PhillipsChevron PhillipsChevron Phillips is a chemical producer jointly owned by Chevron Corporation and ConocoPhillips. The company was formed July 1, 2000 by merging the chemicals operations of both Chevron Corporation and Phillips Petroleum Company. A 50/50 venture, the company continues to be governed by a board of...
- List of industrial disasters
- Phillips explosion of 1999Phillips explosion of 1999Two contractors were killed and three men were injured in an explosion on the morning of Wednesday, June 23, 1999, at Phillips Petroleum Company's K-Resin plant in its chemical complex at 1400 Jefferson Road, Pasadena, Texas 77506. An alarm sounded at 11:30 am when the blast occurred and a fire...
- Phillips explosion of 2000Phillips explosion of 2000At approximately 1:22 p.m. CT on March 27, 2000, an explosion and fire responsible for one death and 71 injuries occurred at Phillips Petroleum's Houston Chemical Complex at 1400 Jefferson Road, Pasadena, Texas 77506...