Analysis of Chemical Plant Explosion Caused by Failure to Comply with Equipment Operating Limits (Louisville, USA)
In November 2024, an explosion caused by exceeding the safe operating limits of equipment occurred at the Givaudan Sense Colour chemical plant in Louisville, Kentucky, USA, killing two workers and seriously injuring three others. The U.S. Chemical Safety Board (CSB) recommended strict compliance with safe operating limits and a clear awareness of equipment limits when operating chemical facilities. On-site practitioners must constantly monitor operating conditions, such as design pressure and temperature, and inspect emergency shutdown systems.
Summary
- In November 2024, an explosion occurred at the Givaudan Sense Colour chemical plant in Louisville, Kentucky, USA, killing two workers and seriously injuring three others.
- An investigation by the U.S. Chemical Safety Board (CSB) identified operating the equipment outside of its safe operating limits as a key cause of the accident.
- Process safety management, which involves clearly understanding and complying with design standards and safety limits when operating chemical equipment, is essential.
Incident Overview
| Item | Details |
|---|---|
| Date/Time | November 2024 |
| Location | Givaudan Sense Colour Chemical Plant, Louisville, Kentucky, USA |
| Accident Type | Explosion |
| Casualties | 2 fatalities, 3 injuries |
Key Cause Analysis
Q. Why did this accident occur?
- Equipment Factors: The chemical reactor or related equipment operated beyond its allowable safe operating limits (presumed).
- Management Factors: Operator's lack of awareness regarding the physical limits of the equipment and inadequate Process Safety Management (PSM) (presumed).
- Human Factors: Inadequate emergency response and shutdown timing when abnormal signs or limits of the equipment were reached (presumed).
Why It Is Dangerous on Site
In actual workplaces, equipment is often forced to operate close to its design capacity or limits such as pressure and temperature to increase productivity or shorten working hours. In particular, in chemical processes, minute changes in temperature or pressure can lead to rapid runaway thermal reactions or pressure build-ups, causing major explosions in an instant. If operators do not accurately recognize the physical limits of the equipment and the risks of chain reactions, they may treat warning alarms as simple malfunctions or miss the appropriate shutdown timing, leading to fatal major disasters.
Prevention Checklist
- Are safe operating limits (temperature, pressure, flow rate, etc.) for each chemical equipment clearly defined and documented?
- Are interlocks and emergency shutdown systems that automatically operate when safety limits are exceeded during equipment operation functioning properly?
- Are workers fully aware of the equipment's operating limits and emergency response procedures?
- Are equipment malfunctions and abnormal reaction risks identified and improved through periodic process hazard analyses (HAZOP, etc.)?
- Are the capacity and condition of pressure relief devices (safety valves, rupture discs, etc.) properly maintained?
- Are the alarm setpoints of the equipment monitoring system set sufficiently lower than the safety limits to enable early warning?
Related Regulations
- Occupational Safety and Health Act, Article 44 (Preparation and Submission of Process Safety Reports, etc.): An employer who owns hazardous or dangerous facilities prescribed by Presidential Decree shall prepare a process safety report and submit it to the Minister of Employment and Labor for review in order to prevent process accidents.
- Rules on Occupational Safety and Health Standards, Article 261 (Installation of Safety Valves, etc.): An employer shall install safety valves, etc., to prevent rupture due to overpressure in piping such as pressure vessels and multi-stage compressors.