Ammonium Nitrate Explosion and Fire

On the evening of April 17, 2013, local officer Rick Jervis discovered smoke venting from the fertilizer building, and when he looked closer, he saw flames, indicating there was a structural fire. The officer called in the fire and then began evacuating residents who lived within a one-mile radius of the West Fertilizer Company facility. More police officers were dispersed to establish traffic control in several different locations around the community. The West Volunteer Fire Department was dispatched to the scene of the fire. Less than 20 minutes after the first officer reported seeing smoke, the fertilizer storage building was engulfed in flames and detonated with the explosive power of 20,000-40,000 pounds of TNT.

As a result of the blast, 15 people lost their lives and an additional 260 more were injured, including emergency personnel and members of the community, according to the U.S. Chemical Safety and Hazard Investigation Board (CSB). The blast destroyed the entire West Fertilizer Company facility and caused an estimated $250 million in insurance-related damages to homes, schools, and a nursing home. The company filed for bankruptcy after the incident.

Since 1916, there have been 32 Fertilizer-Grade Ammonium Nitrate (FGAN) incidents which have caused devastating property damage and an estimated 654 deaths. In their 264-page incident report, the CSB provided several recommendations for safety and risk management. They also called on government and industry organizations to improve safety measures for FGAN. Because there are large holes in these PSM regulations, the process industries should follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEP) in the design, operation, maintenance, and management of chemical processes to protect the safety, health, and welfare of the public.

The Fertilizer Institute has published online guidelines, tools, and informational resources to help the industry understand the dangers associated with ammonium nitrate (AN). Please take advantage of these valuable tools by visiting their website.

Key CSB Findings

Unsafe Storage of Combustible Materials

By storing improperly near the FGAN pile the excess combustible materials used for the construction of the West Fertilizer Company facility, employees not only increased the progression and intensity of the fire; they also increased the potential severity of a fire.

Lack of a Fire Detection and Response System

By not installing a fire detention system, the West Fertilizer Company failed to provide early detection for emergency response, preventing them from arriving in time to fight the blaze. The company also failed to protect potential building occupants in their facility. OSHA explains, “Automatic fire detection systems, when combined with other elements of an emergency response and evacuation plan, can significantly reduce property damage, personal injuries, and loss of life from fire in the workplace.”

Lack of Up-To-Date Land Use Plans

When the facility first opened, there were no zoning issues as it was surrounded by fields. Over time, the buffer zone that was originally present had disappeared. For example, in 2013 the West Intermediate School for 4th and 5th graders was located only 550 feet away from the fertilizer plant. To take adequate risk management steps, the plant needed an updated facility siting that reflected the population growth in West, TX. The proximity of residential areas to the fertilizer storage building fire caused significant destruction to the community.

Our Recommendations

Hazard Analysis (PHA/DHA)

Process hazard analyses (PHAs) have been conducted for decades in many industries, but no matter what the industry, the premise is the same: identify hazards, understand their causes and consequences, implement safeguards, and the risks will be managed. The ioKinetic team uses qualitative techniques to judge risk and to pinpoint weaknesses in the design and operation of facilities. Detailed analysis is done using industry-standard techniques such as Hazard and Operability (HAZOP), What-if?, and Checklist (including Facility Siting and Human Factors). The studies are prepared using PHAGlobal^® software from our exclusive partner, ioMosaic Corporation. We recommend integrating PHAGlobal^® with the Process Safety Enterprise^® platform as it makes it easier for companies to conduct a PHA, track recommendations and/or action items, and deliver secure access to all information.

Facility Siting

If prior to the incident the OSHA PSM Standard had applied to retail facilities, the West Fertilizer Company would have had to comply with the regulation and address facility siting as part of its PHA study. On the other hand, by properly applying RAGAGEP and performing a facility siting, this would have identified the close proximity of the storage tanks and FGAN storage warehouse. The CSB investigation noted the FGAN explosion had damaged the facility’s anhydrous ammonia tanks, placing the community at risk for a chemical release.

A quality facility siting study provides you with the data necessary to make informed decisions to address risks from fire, explosions, or toxic substances. The ioKinetic team employs a three-pronged approach when performing facility siting studies (a) identifying the buildings at risk, (b) assessing if the risk is tolerable, and (c) recommending cost-effective risk reduction where applicable to as low as reasonably practicable (ALARP).

Process Safety Training

A facility that questions the “this is the way we've always done it” mindset can prevent blindness to a potential failure in their system. A learning culture fosters an “identify and apply” approach, reducing the likelihood of an incident. By encouraging knowledge sharing in your organization, you improve overall performance, improve communication, and empower your team. Building a learning culture is a vital part of chemical accident risk management. ioKinetic can help. Our training experts can develop and customize process safety training materials to suit your organization's specific needs and requirements and help you prevent incidents.

We Can Help

ioKinetic process safety specialists can provide your company with independent and unbiased consulting guidance that is specific to your facility and industry needs. To learn more about how we can help you manage risk, contact us today or call us at 1-844-ioKinetic.