Comprehensive Failure Analysis in Tehran Refinery Fire Accident: Application of Accimap Methodology and Quantitative Domino Effect Analysis

Major domino fire accidents in the process industry require careful investigation using proper tools due to their potent effects on the chemical supply chain. Domino accidents in a chemical process systems refer to accident in which fire and explosions escalate from one initiating system to multiple systems. This study investigated the dimensions and causes of the Tehran Oil Refinery accident using the AcciMap method and quantitative domino effect analysis. This accident happened on June 2, 2021, in which a catastrophic leak in one of the slop storage tanks in the refinery caused a severe fire that eventually led to the complete burning of six tanks of a common dike wall. In this study, the influencing causes of the accident were extracted. The present study proposed control strategies based on Accimap method to prevent similar accidents. Furthermore, a new, safer design for tank layout is presented using a quantitative domino effect analysis. The findings showed that corrosion in the main tank rings was the primary reason for slop leakage. In addition, (a) weakness in the incident command system (ICS), (b) failure to implement thr process safety management (PSM) standards, and (c) deficiency in monitoring the implementation of safety regulations at governmental and legislative levels were contributing factors for the fire spread. In addition, (A) the unsafe arrangement of tanks, (B) failure to consider probable consequences, and (C) lack of a dedicated dike wall for each reservoir escalated fire from the main tank to other tanks. This study provided control solutions in management and supervision at all layers by applying the Accimap method and domino effect analysis and proposing a safer layout for re-designing the tanks.