For more information, go to: Formosa Point Comfort Investigation Information Page

Washington, DC, April 20, 2007-The U.S. Chemical Safety Board (CSB) has officially notified Kellogg, Brown, and Root (KBR), the engineering firm for a Texas petrochemical facility that experienced a propylene explosion in 2005, that its response to two CSB safety recommendations exceeded the Board's expectations.

The accident occurred on October 6, 2005, at the Formosa Plastics Point Comfort, Texas, facility when a forklift and trailer snagged and broke a propylene valve. This caused the release of a significant volume of propylene which ignited, creating a large fire. The initial explosion knocked several operators to the ground and burned two men, one seriously. Fourteen workers sustained minor injuries while evacuating the complex.

On July 20, 2006, the CSB issued the case study Fire at Formosa Plastics: Evaluating Process Hazards to detail the findings and recommendations of this investigation. The report found that the propylene valve was unguarded and vulnerable to being hit by vehicles. CSB also found that the steel supports that collapsed in the explosion were not fireproofed. This caused the failure of pipes designed to carry flammable hydrocarbons to the unit's flare system, where they could be safely burned. The investigation also found that the process unit lacked remote isolation valves that could have been used to reduce the severity of the fire.

The Board recommended that KBR communicate the findings and recommendations of the case study to all companies that contracted with KBR, or its predecessor M.W. Kellogg, for plant designs similar to those of the Point Comfort facility. KBR went beyond the CSB's recommendation by sending the CSB case study to all of their North American clients, not exclusively to those with similar ethylene plants.

The Board also recommended that KBR communicate the case study findings and recommendations to its petrochemical process plant design engineers. The firm implemented new work practices for all of its petrochemical process plant design engineers that address the critical need to use recognized and generally accepted good engineering practices in their designs. KBR also issued a directive to all its engineering offices on the subject.

"It is with great pleasure that the Board voted that KBR has implemented the recommendations and made sweeping changes to prevent accidents. When companies implement recommendations and go above and beyond, they deserve recognition. Other companies should examine their leadership and follow its example," said CSB Chairman Carolyn W. Merritt.

This implementation of CSB recommendations by KBR demonstrates a commitment to improved safety that goes beyond the minimum required to close the recommendation. The Board voted unanimously to designate the status of two recommendations to KBR as "Closed-Exceeds Recommended Action."

The CSB is an independent federal agency charged with investigating industrial chemical accidents. The agency's board members are appointed by the president and confirmed by the Senate. CSB investigations look into all aspects of chemical accidents, including physical causes such as equipment failure as well as inadequacies in regulations, industry standards, and safety management systems.

For more information, contact: Public Affairs Specialists Hillary Cohen (202) 261-3601 or Jennifer Jones (202) 261-3603.