Corroded pipe elbow linked to Philly refinery blast, fire

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The US Chemical Safety Board (CSB) has determined that a corroded piece of pipe led to an explosion at the Philadelphia Energy Solutions refinery.

The interim head of the board also said it was fortunate that the release of a chemical that led to the blast did not have more serious consequences.

The refinery is now winding down remaining operations after filing for Chapter 11 bankruptcy protection in Delaware after the blast. It was the second filing for the company.

Philadelphia Energy, which has two refineries, is part of a cluster of sites in the areas that include the PBF Delaware City location.

The refinery struggled with financial issues after its sale to a private equity firm with its former owner also having an interest.

A factual update into the June 21 explosion and fire noted that a pipe elbow, which had corroded to about half the thickness of a credit card, appears to have ruptured in the refinery’s alkylation unit, releasing process fluid that included over 5,000 pounds of hydrofluoric acid, or HF.

The leaking fluid formed a large ground-hugging vapor cloud. Two minutes later, the cloud ignited, causing a massive fire and explosions.

Interim Chemical Safety Board Executive Dr. Kristen Kulinowski said, “Since 2015, the CSB has investigated three major incidents at refineries that utilize HF for alkylation. Incidents in Superior, WI, and Torrance, CA, fortunately did not result in an HF release. That was not the case here in Philadelphia. Though the main tank holding HF was not breached, HF was a component of the process fluid released from the alkylation unit. We are lucky there were no serious injuries or fatalities.”

While the CSB’s investigation is still ongoing, the factual update notes important details of the incident collected through interviewing witnesses, gathering evidence and piecing together the events that led to the explosion:

  • The piping was susceptible to corrosion from the hydrofluoric acid that was in the process fluid. The elbow that ruptured corroded faster than the rest of the piping in this part of the process.
  • While pipe thickness in this section of the unit was periodically measured to monitor corrosion rates, the thickness of the elbow that failed had not been monitored for corrosion. The piece of piping that failed had a high nickel and copper content. Various industry publications have found that carbon steel with a higher percentage of nickel and copper corrodes at a faster rate than carbon steel with a lower percentage when used in a process with hydrofluoric acid.
  • A secondary event at the PES refinery occurred when the V-1 Treater Feed Surge Drum ruptured, which launched a fragment of the vessel weighing 38,000 pounds across the Schuylkill River. Two other large fragments landed within the PES Refinery.

CSB Supervisory Investigator Lauren Grim said, “Corrosion is not a new issue for the CSB. In its prior investigation of a 2012 Chevron Refinery fire we determined that corrosion caused the rupture of a piping component. Similarly, the 2009 Silver Eagle refinery fire was also caused by the failure of piping that had thinned due to corrosion.”

The CSB’s interim animation details the events which occurred at the PES refinery on June 21st, view the full animation below.

During s news conference Interim Executive Kulinowski noted that moving forward the CSB is examining the need for more robust reviews of corrosion mechanisms as well as looking more closely at the use of HF in the refining process.

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