CUI Major Incident# 3: Repsol A Coruna Refinery Fire

Date and Place of the Incident:

On October 10, 2012, a fire started in the fluid catalytic cracking unit (FCC) of a refinery in Madrid, Spain.

Summary of the Incident:

1. Fluid catalytic cracking unit (FCC) of the refinery was caught in fire after a corroded pipe allowed the escape of 5 tonnes of vacuum fuel oil (a flammable substance).
2. The insulation of the pipe suffered external corrosion which led to gradual degradation.
3. The facility activated an onsite emergency plan and was raised up to partial emergency level.

Root Cause of the Incident:

1. Corrosion under insulation was the root cause of the incident.
2. The 6 inches pipe ruptured because external corrosion formed at the insulating material and the inner face of an elbow in the aerial pipe rack.
3. The defective pipe allowed the release of vacuum fuel oil.

Financial Loss to Freedom Industries:

The fire caused substantial damage to the refinery as production was halted due to repair and inspection works.

Environmental Impact of the Incident:

A small area of the FCC unit was damaged, 2 inches pipe feeding the torch and a ¾ inches pipe of flushing were destroyed and electric and instrumental wiring were also damaged.

Fatality or injury due to the Incident:

No injuries or fatalities were recorded during the time of the incident.

 Non-Compliance of Safety Guidelines and Reliability Practices:

1. Lack of corrosion control program in place.
2. Insufficient monitoring and inspection of process pipes.

Recommendations to Avoid Corrosion:

1. Perform adequate pipe inspection and assessment of pipes.
2. Implement corrosion control program for process pipes.
3. Set up active controls for quick detection of corrosion or any structural defect.

Links to the photos/videos:

The websites below provide full access to the incident report, useful insights, and related images.

https://emars.jrc.ec.europa.eu/en/emars/accident/view/0828cfea-9c2e-fd71-5a67-8fb7600cab6d

https://publications.jrc.ec.europa.eu/repository/bitstream/JRC84661/lbna26331enn.pdf