Investigating the catastrophic roof failure of a fatty acid storage tank: Causes, mechanisms, and safety implications

This paper investigates the catastrophic failure of the roof weld on a carbon steel storage tank at a fatty acids plant, which was attributed to pressure overload. The incident resulted in the tank's roof, weighing over 5 tons and spanning 8 m in diameter, being propelled 25 m from the tank. Despite installing several safety devices, including pressure regulating valves, pressure indicator controls, and pressure vacuum relief valves, inadequate maintenance led to their malfunction. This study examines the mechanisms and causes behind the failure, highlighting the crucial role of regular maintenance in ensuring the functionality of safety instruments. While neither toxic nor flammable, the plant's compressed air system poses a significant hazard due to the energy stored at slight overpressure, necessitating vigilant management by the safety department. The findings underscore the importance of robust maintenance strategies and procedural adherence to prevent similar incidents, enhancing industrial storage systems' overall safety and reliability. © 2024 Elsevier Ltd