Esso Longford Gas Explosion - Explosion at Longford

Explosion At Longford

During the morning of Friday 25 September 1998, a pump supplying heated lean oil to heat exchanger GP905 in Gas Plant No. 1 went offline for four hours, due to an increase in flow from the Marlin Gas Field which caused an overflow of condensate in the absorber.

A heat exchanger is a vessel that allows the transfer of heat from a hot stream to a cold stream, and so does not operate at a single temperature, but experiences a range of temperatures throughout the vessel. Temperatures throughout GP905 normally ranged from 60 °C to 230 °C (140 °F to 446 °F). Investigators estimated that, due to the failure of the lean oil pump, parts of GP905 experienced temperatures as low as −48 °C (−54 °F). Ice had formed on the unit, and it was decided to resume pumping heated lean oil in to thaw it. When the lean oil pump resumed operation, it pumped oil into the heat exchanger at 230 °C (446 °F)—the temperature differential caused a brittle fracture in the exchanger (GP905) at 12.26pm.

About 10 metric tonnes of hydrocarbon vapour were immediately vented from the rupture. A vapour cloud formed and drifted downwind. When it reached a set of heaters 170 metres away, it ignited. This caused a deflagration (a burning vapour cloud). The flame front burnt its way through the vapour cloud, without causing an explosion. When the flamefront reached the rupture in the heat exchanger, a fierce jet fire developed that lasted for two days.

The rupture of GP905 led to other releases and minor fires. The main fire was an intense jet fire emanating from GP905. There was no blast wave—the nearby control room was undamaged. Damage was localised to the immediate area around and above the GP905 exchanger.

Peter Wilson and John Lowery were killed in the accident and eight others were injured.

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