ARGUELLESS v. Kellogg Brown & Root, Inc.

222 S.W.3d 714, 2007 Tex. App. LEXIS 2339, 2007 WL 896280
CourtCourt of Appeals of Texas
DecidedMarch 27, 2007
Docket14-04-01022-CV
StatusPublished
Cited by27 cases

This text of 222 S.W.3d 714 (ARGUELLESS v. Kellogg Brown & Root, Inc.) is published on Counsel Stack Legal Research, covering Court of Appeals of Texas primary law. Counsel Stack provides free access to over 12 million legal documents including statutes, case law, regulations, and constitutions.

Bluebook
ARGUELLESS v. Kellogg Brown & Root, Inc., 222 S.W.3d 714, 2007 Tex. App. LEXIS 2339, 2007 WL 896280 (Tex. Ct. App. 2007).

Opinion

OPINION

KEM THOMPSON FROST, Justice.

This case arises from a terrible explosion and fire at a large chemical complex, resulting in personal injury to many workers. After some of the injured workers filed negligence claims against companies that allegedly had provided services to their employer, the trial court rendered a summary judgment that the workers take nothing on their claims against the service providers. On appeal, the workers assert that the judgment in favor of the service providers lacks finality and that the trial court erred in granting summary judgment because (1) there is substantial evidence the service providers owed the workers a duty of care, (2) there is substantial evidence the service providers’ alleged negligence was a proximate cause of the workers’ injuries, (3) there is substantial evidence the employer’s actions leading up to the explosion were not a new and independent cause of the explosion, and (4) there are fact issues on all matters raised by the service providers. We conclude the judgment is final. We also conclude that, as a matter of law under the applicable standard of review, any breach of the duties owed by the service providers did not proximately cause the workers’ injuries. Accordingly, we affirm the trial court’s judgment.

I. FACTUAL BACKGROUND 1

Phillips Petroleum Company initiated operation of the K-Resin Unit in Phillips Petroleum Company’s Houston Chemical Complex (hereinafter “K-Resin Unit”) in 1978 to produce a styrene-butadiene block copolymer called “K-Resin.” K-Resin is a clear, flexible plastic that has many uses in the food and medical packaging industries. Understanding the K-Resin manufacturing process and the operation of the K-Resin Unit is essential to the proper resolution of the issues in this appeal.

A. The K-Resin Process

One of the raw materials used in the reactors at the K-Resin Unit is a diene monomer called 1,3-butadiene (hereinafter “butadiene”). Because it is a monomer, butadiene will polymerize or react with itself. The butadiene arrives at the K-Resin Unit by a dedicated pipeline and is stored in a 200,000-gallon spherical tank. As it arrives through the pipeline and is stored in this tank, the butadiene contains an inhibitor called “TBC” that inhibits bu-tadiene from reacting with itself to form polymers. 2 Butadiene that contains such an inhibitor is called inhibited or wet buta-diene, and butadiene that lacks any such inhibitor is called uninhibited or dry buta-diene. The wet butadiene in the spherical tank recirculates continuously through a refrigerated chiller to maintain a temperature of approximately 45 degrees Fahrenheit. The presence of the inhibitor in the butadiene and the low temperature prevent the butadiene from reacting with itself to form polymers while it is stored in the spherical tank.

To create the desired product, steps are taken to ensure the butadiene is free of inhibitor before it is fed to the reactors. The wet butadiene is moved from the spherical tank to activated alumina *718 molecular sieves or dryers, which remove impurities, including inhibitor, from the butadiene. Because the dry butadiene is normally fed to the reactors intermittently and because there are usually several reactors in operation, the dry butadiene is distributed to either the East or the West Dry Butadiene Tank to ensure that there is adequate dry butadiene to feed to the reactors.

At the time of the explosion, each of the Dry Butadiene Tanks was eight feet in diameter and approximately forty feet tall. Each tank had a capacity of 13,000 gallons. Only one Dry Butadiene Tank was used at a time. When a tank was not in service, Phillips employees would empty it, remove a form of butadiene polymer known as “popcorn polymer” from inside, and then place the tank on stand-by to go into service in place of the other tank. The dry butadiene in the tank that is in service circulates continuously through a charge filter and then a chiller. The filter removes rust, polymers, and any other particulates that may be in the dry butadiene. The cooler keeps the butadiene cool while the substance is awaiting transfer to the reactors. This low temperature is necessary to prevent the butadiene from reacting with itself to form polymers while it is being stored in the Dry Butadiene Tanks. While butadiene has a tendency to react with itself to form various polymers, at low temperatures the rates of these reactions are very slow. However, as the temperature increases, the reaction rates increase rapidly.

The Dry Butadiene Tank being used to feed the reactors is isolated from the other tank as the dry butadiene is pumped to the reactor as and where needed. The Buta-diene Charge Pump moves the dry buta-diene through a charge filter to a reactor. In the reactor, the dry butadiene is combined with styrene to produce K-Resin.

The Danger of Popcorn Polymerization in Dry Butadiene

“Popcorn polymer” is a butadiene polymer in which there is considerable cross-linking within the polymer. This cross-linking causes the popcorn polymer to be hard and also insoluble in the butadiene. Popcorn polymer grows when the molecular bonds in its cross-linked structure break to form an active site where buta-diene can react, attach, and become part of the popcorn. This growing process causes a popping sound, which is the origin of the name “popcorn polymer.” As the popcorn polymer grows, stresses are formed within the popcorn that cause additional bonds to break and form more active sites, which can cause further growth of the popcorn polymer. The formation of popcorn polymer is only a problem in the part of the K-Resin process that occurs after the buta-diene passes through the dryers. Before this point in the process, the butadiene contains inhibitor, which prevents popcorn growth. But after the butadiene passes through the dryers into the Dry Butadiene Tanks, the butadiene has no inhibitor, and popcorn polymer can form. Butadiene’s ability to react with itself to form popcorn polymer affects temperature, and, more importantly, pressure.

At any given time, a Dry Butadiene Tank containing butadiene contains a combination of liquid and vapor butadiene in the tank. “Popcorn seeds” form when small amounts of oxygen are allowed into the tank. The reaction that creates a popcorn seed liberates heat. Once the popcorn seed forms, it is then free to react with the dry, liquid butadiene that surrounds it. By reacting with the surrounding liquid butadiene, the popcorn seed can grow. Each reaction in which the popcorn seed grows liberates heat. Consequently, the continuing popcorn polymer growth generates heat that increases the tempera *719 ture inside the tank. Temperature increases, in turn, cause the pressure inside the tank to increase. The rate of growth of popcorn polymerization accelerates as the temperature and pressure increase inside the tank. Because the growth of popcorn polymerization increases temperature and pressure, this process feeds on itself. Once the temperature and pressure inside the tank reach high enough levels, the reaction rate continues to accelerate until it eventually accelerates very rapidly. This rapid acceleration, in turn, causes the pressure to increase dramatically in a very short period of time.

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Bluebook (online)
222 S.W.3d 714, 2007 Tex. App. LEXIS 2339, 2007 WL 896280, Counsel Stack Legal Research, https://law.counselstack.com/opinion/arguelless-v-kellogg-brown-root-inc-texapp-2007.