Disaster Flixborough

Parker, R. J. (Chairman), 1975. The Flixborough Disaster. Report of the Court of Inquiry. London HM Stationery Office. 

In the Flixborough disaster, one of six reactors in series, through which hot cyclohexane was passed, was removed from service (see Figure 2.1). Each reactor was connected by a short pipe with a bellows at each end to allow for expansion. The fifth reactor was replaced by a temporary bypass pipe with two bends in it to allow for differences in height between reactors 4 and 6. Because the bypass was not properly supported and had a bellows at either end, it moved when there were pressure variations. This movement eventually caused the bellows to fail, releasing 50 tons of cyclohexane which exploded, killing 28 men. 

The Flixborough Disaster Report of the Court of Enquiry." Formal Investigation into Accident on 1st June 1974 at the Nypro Factory at Flixborough. London Her Majesty s Stationery Office. 

In the Flixborough disaster (see Chapter 9), there was evidence that the stress corrosion cracking of a stainless-steel pipe had been caused by zinc contamination from galvanised-wire supporting lagging. 

If the mixture (or a dust cloud) is confined, even if only by surface irregularities or local partial obstructions, significant pressure effects can occur. Fuel-air mixtures near to stoicheiometric composition and closely confined will develop pressures of several bar within milliseconds, and material damage will be severe. Unconfined vapour explosions of large dimensions may involve higher flame velocities and significant pressure effects, as shown in the Flixborough disaster. 

Much has been written about Loss Prevention, and HAZOP studies in particular, the volume of publications has grown considerably since the Flixborough disaster in 1974. Standards, Codes of Practice and Acts of Parliament provide essential information, and the references included here provide a good overview of the subject, and a basis for more detailed study. 

The Flixborough Disaster and the Lessons We Should Never Forget... 

Warner, Sir Fredrick, The Flixborough Disaster, Chemical Engineering Progress 71 no. 9, Sept. 1975 pp. 77-84. 

Some of the most tragic and well-remembered accidents also had a start with a mini-modification made with a hose connection. The Bhopal Tragedy, the Three-Mile Island Incident, and the Flixborough Disaster were initiated by the improper use of hoses. 

The Flixborough disaster in June, 1974 (Lees, 1980), is an example of a case where a modification was introduced into a mostly well designed and constructed plant. This modification destroyed the plant s integrity and contributed to a major accident. The modification was made when a reactor failed (a large crack had formed). The modification was inadequate and the remaining reactors were not examined. 

Storage Facilities The Flixborough disaster (Lees, 1980) occurred on June 1, 1974, and involved a large, unconfined vapor cloud explosion (or explosions—there may have been two) and Fire that killed 28 people and injured 36 at the plant and many more in the surrounding area. The entire chemical plant was demolished and 1821 houses and 167 shops were damaged. 

The Flixborough disaster and the lessons we should never forget... 

Warner Sir F. The flixborough disaster. Chem Eng Prog I975 77-84. 

You can also find video clips of earlier major incidents including Philhps 66 Pasadena Texas (1989) Piper Alpha Catastrophe (1988) and Flixborough Disaster (1976). No doubt there are many others. 

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