Reciprocating compressors were used to provide cooling for polymerization reactions at Goodyear's Beaumont, Texas, chemical plant. In November 1993, a refrigeration compressor failed catastrophically and resulted in a large propane release followed by a vapor cloud explosion that injured seven associates. The investigation became a complex evaluation and analysis of the process, procedures, machinery, materials, maintenance, and inspection activities. The investigation utilized two different metallurgical examination methods to assist in determining compressor part failure. Finite element analysis was used to analyze stress and predict failure location. The process, equipment, investigation details, and conclusions are presented. The persistence of the team through a difficult investigation resulted in many valuable lessons learned. One root cause was traced to a subtle change made to the compressor seventeen years earlier. Even with 20/20 hindsight, would your PHA team evaluating this MOC have predicted the failure?
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