Carbide Industries Fire and Explosion
Final Report Released On: February 07, 2013
Two workers were killed and two others injured as a result of a fire and explosion that occurred at the Carbide Industries facility located in Louisville, KY; the facility produces calcium carbid... Learn More
Hoeganaes Corporation Fatal Flash Fires
Final Report Released On: January 05, 2012
Three combustible dust incidents over a six month period occurred at the Hoeganaes facility in Gallatin, TN, resulting in fatal injuries to five workers. The facility produces powdered iron and i... Learn More
Oil Site Safety
Final Report Released On: October 27, 2011
On April 13, 2010, the CSB released a safety video, entitled “No Place to Hang Out”. The video tells the story of the tragic deaths of 18-year-old Wade White and 16-year-old Devon Byrd, killed on... Learn More
Texas Tech University Chemistry Lab Explosion
Final Report Released On: October 19, 2011
An explosion severely injured a graduate student at Texas Tech University in Lubbock, Texas, in the chemistry department during the handling of a high-energy metal compound, which suddenly detona... Learn More
DuPont Corporation Toxic Chemical Releases
Final Report Released On: September 20, 2011
On January 23, there was a release of highly toxic phosgene, exposing a veteran operator at the DuPont facility in Belle, West Virginia and resulting in his death one day later.
DuPont offic... Learn More
Goodyear Heat Exchanger Rupture
Final Report Released On: January 27, 2011
On June 11, 2008, one worker was killed and approximately seven others were injured, during a maintenance operation on a heat exchanger. Ammonia overpressured inside the exchanger, causing it to ... Learn More
Bayer CropScience Pesticide Waste Tank Explosion
Final Report Released On: January 20, 2011
Two workers were fatally injured when a waste tank containing the pesticide methomyl violently exploded, damaging a process unit at the Bayer CropScience chemical plant in Institute, West Virgini... Learn More
Xcel Energy Company Hydroelectric Tunnel Fire
Final Report Released On: August 25, 2010
On October 2, 2007, five people were killed and three others injured when a fire erupted 1,000 feet underground in a tunnel at Xcel Energy Company's hydroelectric power plant in Georgetown, Color... Learn More
Kleen Energy Natural Gas Explosion
Final Report Released On: June 28, 2010
Six workers were fatally injured during a planned work activity to clean debris from natural gas pipes at Kleen Energy in Middletown, CT. To remove the debris, workers used natural gas at a high ... Learn More
INDSPEC Chemical Corporation Oleum Release
Final Report Released On: September 30, 2009
On October 11, 2008, a transfer operation overflowed an oleum process tank, filling a vent system and releasing the oleum into a storage building at Indspec Chemical Corporation in Petrolia, Penn... Learn More
Imperial Sugar Company Dust Explosion and Fire
Final Report Released On: September 24, 2009
On February 7, 2008, a huge explosion and fire occurred at the Imperial Sugar refinery northwest of Savannah, Georgia, causing 14 deaths and injuring 38 others, including 14 with serious and life... Learn More
T2 Laboratories Inc. Reactive Chemical Explosion
Final Report Released On: September 15, 2009
On December 19, 2007, four people were killed and 13 others were transported to the hospital when an explosion occured at T2 Laboratories Inc. during the production of a gasoline additive called ... Learn More
Allied Terminals Fertilizer Tank Collapse
Final Report Released On: May 27, 2009
On November 12, 2008 a two-million-gallon liquid fertilizer storage tank collapsed at the Allied Terminal distribution facility in Chesapeake, VA. The incident critically injured two contract wor... Learn More
Little General Store Propane Explosion
Final Report Released On: September 25, 2008
Four people were killed and five others were seriously injured when propane vapors from a storage tank ignited and exploded at the Little General convenience store and gas station in Ghent, West ... Learn More
Barton Solvents Flammable Liquid Explosion and Fire
Final Report Released On: September 18, 2008
On October 29, 2007, a fire and series of explosions occurred at the Barton Solvents chemical distribution facility in Des Moines, Iowa, . The initial fire started in the packaging area while a 3... Learn More
Valero Refinery Propane Fire
Final Report Released On: July 09, 2008
On February 16, 2007, a propane fire erupted at the Valero McKee Refinery in Sunray, Texas, north of Amarillo. Three workers suffered serious burns, and the refinery was forced to shut down. The ... Learn More
Barton Solvents Explosions and Fire
Final Report Released On: June 26, 2008
On July 17, 2007, explosions and fire erupted at the Barton Solvents facility in Valley Center, Kansas, north of Wichita. The incident led to the evacuation of thousands of residents and resulted... Learn More
CAI / Arnel Chemical Plant Explosion
Final Report Released On: May 13, 2008
During the early morning hours of November 22, a powerful explosion destroyed the CAI/Arnel ink and paint manufacturing facility in Danvers, Massachusetts. Scores of nearby homes and businesses w... Learn More
EQ Hazardous Waste Plant Explosions and Fire
Final Report Released On: April 16, 2008
Explosions and fire at a hazardous waste facility forced the evacuation of approximately 16,000 residents from Apex, North Carolina, on October 5, 2006. The incident likely began in the oxidizer ... Learn More
Synthron Chemical Explosion
Final Report Released On: July 31, 2007
One worker was fatally burned and about a dozen others were injured when a powerful explosion devastated the Synthron Inc. chemical manufacturing facility. CSB investigators believe the explosion... Learn More
Emergency Shutdown Systems for Chlorine Transfer
Final Report Released On: June 14, 2007
This bulletin compares two chlorine releases investigated by the CSB. In both, a railcar unloading hose
failed and chlorine was released. In the first incident, an emergency shutdown system malf... Learn More
Partridge Raleigh Oilfield Explosion and Fire
Final Report Released On: June 12, 2007
Three contractors died and one contractor suffered serious injuries in an explosion and fire at the Partridge-Raleigh Oilfield. The contractors, all employees of Stringer Oilfield Services, were ... Learn More
Universal Form Clamp Co. Explosion and Fire
Final Report Released On: April 10, 2007
One fatality and five injuries resulted from an explosion and fire in a mixing room at the Universal Form Clamp facility. Workers were heating and mixing flammable solvents in an open top tank. D... Learn More
BP America Refinery Explosion
Final Report Released On: March 20, 2007
At approximately 1:20 p.m. on March 23, 2005, a series of explosions occurred at the BP Texas City refinery during the restarting of a hydrocarbon isomerization unit. Fifteen workers were killed ... Learn More
Bethune Point Wastewater Plant Explosion
Final Report Released On: March 13, 2007
Two municipal workers died and another was seriously injured while attempting to remove a steel canopy above a methanol storage tank at the Bethune Point wastewater plant operated by the City of ... Learn More
Formosa Plastics Vinyl Chloride Explosion
Final Report Released On: March 06, 2007
On April 23, 2004, five workers were fatally injured and two others were seriously injured when an explosion occurred in a polyvinyl chloride (PVC) production unit at Formosa Plastics in Illiopol... Learn More
DPC Enterprises Chlorine Release
Final Report Released On: February 28, 2007
On November 17, 2003, there was a release of chlorine gas from the DPC Enterprises chlorine repackaging facility in Glendale, Arizona, near Phoenix. Fourteen people, including ten police officers... Learn More
Combustible Dust Hazard Investigation
Final Report Released On: November 09, 2006
In 2003, the CSB launched investigations of three major industrial explosions involving combustible powders. These explosions - in North Carolina, Kentucky, and Indiana - cost 14 lives and caused... Learn More
Valero Refinery Asphyxiation Incident
Final Report Released On: November 02, 2006
Two contract employees were overcome and fatally injured by nitrogen as they performed maintenance work near a 24-inch opening on the top of a reactor. One of the workers died attempting rescue. ... Learn More
Positive Material Verification: Prevent Errors
Final Report Released On: October 15, 2006
On July 28, 2005, 4 months after a devastating
incident in the Isomerization (Isom) Unit that killed
15 workers and injured 180, the BP Texas City refinery
experienced a major fire in the Resi... Learn More
Formosa Plastics Propylene Explosion
Final Report Released On: July 20, 2006
A forklift towing a trailer collided with a line containing highly flammable liquid propylene, causing a release and a vapor cloud explosion. Sixteen workers were injured, the process unit was he... Learn More
Praxair Flammable Gas Cylinder Fire
Final Report Released On: June 15, 2006
On June 24, 2005, fire swept through thousands of flammable gas cylinders at the Praxair gas repackaging plant in St. Louis, Missouri. Dozens of exploding cylinders were launched into the surroun... Learn More
Marcus Oil and Chemical Tank Explosion
Final Report Released On: June 06, 2006
On the evening of December 3, a storage tank failed catastrophically at the Marcus Oil and Chemical polyethylene wax facility in Houston. The blast, which was felt up to 20 miles from the plant s... Learn More
MFG Chemical Inc. Toxic Gas Release
Final Report Released On: April 11, 2006
On the evening of April 12, 2004, a chemical reactor overheated at the MFG Chemical manufacturing plant, releasing toxic allyl alcohol vapor. The resulting cloud sent 154 people to a local hospit... Learn More
Sterigenics Ethylene Oxide Explosion
Final Report Released On: March 30, 2006
At approximately 3:00 p.m. on August 19, 2004, an explosion occurred inside an ethylene oxide sterilization chamber and an associated thermal oxidizer at the Sterigenics facility in Ontario, Cali... Learn More
Acetylene Service Company Gas Explosion
Final Report Released On: January 26, 2006
On January 25, 2005, a gas explosion killed three workers at the Acetylene Service Company plant in Perth Amboy, NJ. The blast originated in a wooden shed located near six large storage tanks tha... Learn More
Giant Industries Refinery Explosions and Fire
Final Report Released On: October 26, 2005
On April 8, 2004, four workers were seriously injured when highly flammable gasoline components were released and ignited at the Giant Industries Ciniza refinery, east of Gallup, New Mexico. The ... Learn More
Hayes Lemmerz Dust Explosions and Fire
Final Report Released On: September 27, 2005
On the evening of October 29, 2003, a series of explosions severely burned two workers, injured a third, and caused property damage to the Hayes Lemmerz manufacturing plant in Huntington, Indiana... Learn More
Honeywell Chemical Incidents
Final Report Released On: August 08, 2005
On July 20, 2003, there was a release of chlorine gas from the Honeywell refrigerant manufacturing plant in Baton Rouge, Louisiana. The accident resulted in the hospitalization of four plant work... Learn More
CTA Acoustics Dust Explosion and Fire
Final Report Released On: February 15, 2005
On February 20, 2003, an explosion and fire damaged the CTA Acoustics manufacturing plant in Corbin, Kentucky, fatally injuring seven workers. The facility produced fiberglass insulation for the ... Learn More
Isotec/Sigma Aldrich Nitric Oxide Explosion
Final Report Released On: August 24, 2004
On September 21, 2003, a violent explosion destroyed an underground distillation tower at the Isotec chemical manufacturing plant in Miami Township, Ohio, injuring one worker. The explosion ruptu... Learn More
Technic Inc. Ventilation System Explosion
Final Report Released On: August 20, 2004
On February 7, 2003, a worker was seriously injured in an explosion at Technic Inc. in Cranston, Rhode Island. The explosion occurred during maintenance on a ventilation system connected to multi... Learn More
Sodium Hydrosulfide: Preventing Harm
Final Report Released On: July 15, 2004
This Safety Bulletin is published to increase awareness of the hazards associated with NaHS and to outline safety practices to minimize the potential for harm to workers and the public.... Learn More
Removal of Hazardous Material from Piping Systems
Final Report Released On: July 15, 2004
This Safety Bulletin identifies specific tasks that facilities should
include in all work activities involving piping or equipment opening to
ensure the complete removal of hazardous material. ... Learn More
D.D. Williamson & Co. Catastrophic Vessel Failure
Final Report Released On: March 12, 2004
On the morning of April 11, 2003, one worker was killed at the D.D. Williamson food additive plant in Louisville, Kentucky, when a process vessel became overpressurized and failed catastrophicall... Learn More
Catalyst Systems Inc. Reactive Chemical Explosion
Final Report Released On: October 29, 2003
On January 2, 2003, a vacuum dryer holding nearly 200 pounds of benzoyl peroxide exploded at the Catalyst Systems Inc. production facility in Gnadenhutten, Ohio. Employees were in the process of ... Learn More
First Chemical Corp. Reactive Chemical Explosion
Final Report Released On: October 15, 2003
On October 13, 2002, a violent explosion occurred in a chemical distillation tower at First Chemical Corporation in Pascagoula, Mississippi, sending heavy debris over a wide area. Three workers i... Learn More
Kaltech Industries Waste Mixing Explosion
Final Report Released On: September 30, 2003
On April 25, 2002, an explosion occurred at Kaltech Industries, a sign manufacturer in the Chelsea neighborhood of New York City, injuring 36 people seriously enough to seek hospital treatment, i... Learn More
Environmental Enterprises Hydrogen Sulfide Release
Final Report Released On: September 17, 2003
On December 11, 2002, one maintenance employee was overcome when he inhaled hydrogen sulfide gas from a waste processing vessel at Environmental Enterprises, a hazardous waste treatment company i... Learn More
BLSR Operating Ltd. Vapor Cloud Fire
Final Report Released On: September 17, 2003
On January 13, 2003, a vapor cloud fire erupted at the BLSR Operating Ltd. oilfield waste disposal facility near Rosharon, Texas, south of Houston. The fire occurred as two vacuum trucks were del... Learn More
Hazards of Nitrogen Asphyxiation
Final Report Released On: June 25, 2003
Every year people are killed by breathing “air” that contains too little
oxygen. Because 78 percent of the air we breathe is nitrogen gas,
many people assume that nitrogen is not harmful. Howev... Learn More
DPC Enterprises Chlorine Release
Final Report Released On: May 01, 2003
On August 14, 2002, a chlorine transfer hose ruptured during a rail car unloading operation at the DPC Enterprises chlorine repackaging facility near Festus, Missouri. The hose rupture ultimately... Learn More
Georgia-Pacific Corp. Hydrogen Sulfide Poisoning
Final Report Released On: November 20, 2002
On January 16, 2002, highly toxic hydrogen sulfide gas leaked from a sewer manway at the Georgia-Pacific Naheola mill in Pennington, Alabama. Several people working near the manway were exposed t... Learn More
Improving Reactive Hazard Management
Final Report Released On: September 17, 2002
In August 2000, following its investigation of a serious reactive incident at Morton International, the Board initiated a comprehensive review of reactive hazards nationwide. The purpose of the ... Learn More
Motiva Enterprises Sulfuric Acid Tank Explosion
Final Report Released On: August 28, 2002
On July 17, 2001, an explosion occurred at the Motiva Enterprises refinery in Delaware City, Delaware. A work crew had been repairing a catwalk above a sulfuric acid storage tank farm when a spar... Learn More
BP Amoco Thermal Decomposition Incident
Final Report Released On: May 20, 2002
On March 13, 2001, three people were killed as they opened a process vessel containing hot plastic at the BP Amoco Polymers plant in Augusta, Georgia. They were unaware that the vessel was press... Learn More
Concept Sciences Hydroxylamine Explosion
Final Report Released On: February 01, 2002
On February 19, 1999, a process vessel containing several hundred pounds of hydroxylamine exploded at the Concept Sciences Inc. production facility near Allentown, Pennsylvania. Employees were di... Learn More
Bethlehem Steel Corporation Gas Condensate Fire
Final Report Released On: December 06, 2001
On February 2, 2001, a fire occurred at Bethlehem Steel Corporation's Burns Harbor mill in Chesterton, Indiana. One Bethlehem Steel millwright and one contractor supervisor died. Four Bethlehem S... Learn More
Management of Change
Final Report Released On: August 28, 2001
The U.S. Chemical Safety and Hazard Investigation Board (CSB) issues this Safety Bulletin to focus attention on the need for systematically managing the safety effects of process changes in the c... Learn More
Tosco Avon Refinery Petroleum Naphtha Fire
Final Report Released On: March 21, 2001
On February 23, 1999, a fire occurred in the crude unit at Tosco Corporation. Avon oil refinery in Martinez, California. Workers were attempting to replace piping attached to a 150-foot-tall frac... Learn More
Herrig Brothers Farm Propane Tank Explosion
Final Report Released On: June 23, 1999
On April 9, 1998, an 18,000-gallon propane tank exploded at the Herrig Brothers farm in Albert City, Iowa. The explosion killed two volunteer firefighters and injured seven other emergency respon... Learn More
Union Carbide Corp. Nitrogen Asphyxiation Incident
Final Report Released On: February 23, 1999
On March 27, 1998, one worker was killed and another seriously injured when they were asphyxiated by nitrogen at Union Carbide Corporation's Taft/Star Manufacturing Plant in Hahnville, Louisiana.... Learn More
Sierra Chemical Co. High Explosives Accident
Final Report Released On: September 23, 1998
On January 7, 1998, two explosions in rapid succession destroyed the Sierra Chemical Company Kean Canyon plant near Mustang, Nevada, killing four workers and injuring six others. ... Learn More