Recent Incident Investigations
Incident
Material Involved
Facility
Client
Recycle gas compressor explosion – Chemical plant
Ethylene
Shell Chemical; Deer Park, Texas
U.S. Environmental Protection Agency
Wastewater storage tank explosion – Refinery
Hydrocarbon vapors
Pennzoil: Rouseville, PA
U.S. Environmental Protection Agency
Hydrocracker Explosion – Refinery
Naphtha
Tosco; Avon, CA
Contra Costa County Health Services
Oil well snubbing operation explosion – Oil exploration
Natural Gas
Sonat Exploration; Bienville Parrish, LA
U.S. Chemical Safety and Hazard Investigation Board
Polymerization reactor explosion – Plastic resin manufacture
Butadiene, Styrene, NBL (Normal Butyl Lithium)
Phillips Chemical; Pasadena, Texas
Attorney
Molten tar storage tank eruption – Asphalt manufacture
Tar, Naphthalene
AlliedSignal; Ironton, OH
Attorney
Wastewater sump explosion – Specialty chemical manufacture
Trinitromethane (TNM), Monochlorobenzene (MCB), Nitrous oxides (NOX)
Lomac; Muskegon, MI
Michigan OSHA
Pyrophoric material fire – Metal alkyl manufacture
TEAL (Triethylaluminum)
Akzo-Nobel; Deer Park, Texas
Attorney
Butadiene storage tank explosion – Plastic resin manufacture
Butadiene, butadiene polyperoxide, popcorn polymer
Phillips Chemical; Pasadena, Texas
Attorney
Toxic material release – Specialty chemical manufacture
Ketene, Diketene
Lonza; Bayport, Texas
Attorney
Toxic material release – Sodium hydrosulfite manufacture
Sulfur Dioxide, Hydrogen Sulfide, Methanol
Celanese/Clariant; Bucks County, AL
Attorney
Unexpected equipment startup – Oriented Strand Board (OSB) manufacture
Rotary Airlock, Wood
Louisiana-Pacific; Silsbee, Texas
Attorney
Toxic material release – Specialty chemical manufacture
Ketene, Diketene
Lonza; Bayport, Texas
Attorney
Energetic release of energy – Fertilizer (ammonia and urea) manufacture
Carbon Dioxide
Agrium; Borger, Texas
Attorney
Waste boiler explosion – Wood pulp and paper mill
Black Liquor
Durango Paper; St. Marys, GA
Attorney
Unexpected equipment movement – Paper mill
Paper machine, Paper
Westvaco/Mead; Evadale, Texas
Attorney
Flash Fire – Refinery heat exchanger
Hexane
Sunoco, La Port, Texas
Attorney
Pyrophoric material fire - Hazardous waste recovery
Phosphorus
Glenn Springs, Columbia, TN
Attorney
Corrosive liquid exposure – Polypropylene resin manufacture
Caustic
Huntsman Petrochemical, Port Neches, Texas
Attorney
Paper Dryer Explosion – Paper mill
Steam
Knowlton Specialty Papers, Watertown, NY
Attorney
Butadiene reactor explosion, Butadiene storage tank explosion – Plastic resin manufacture
Butadiene
Phillips Chemical, Pasadena, Texas
U.S. Environmental Protection Agency & U.S. Department of Justice
Hot, high pressure boiler water exposure – Refinery
Hazardous solvent waste; Liquid waste derived fuel
Ash Grove Cement, Foreman, AR
Attorney
Flash fire - Liquid hazardous waste fire– Cement plant
Hazardous pyrophoric (TEAL) waste
Texas Eastman, Longview, Texas
Attorney
Pyrophoric material fire – Hazardous waste incinerator
CPVC
Noveon, Inc. – Louisville, KY
Attorney
Plastics decomposition & fire – Chlorinated polyvinyl chloride (CPVC) manufacture and compounding
Methyl Iodide
Texas Eastman, Kingsport, TN
Tennessee OSHA
Toxic material release – Specialty chemical manufacture
Gasoline components, light naphtha, hexane
BP Products North America, Texas City, Texas
Attorney
Vapor cloud explosion and resulting fire – Refinery
Plastic Blow Molding
The Plastics Group Fremont. OH
Attorney
Electrocution
Sulfuric Acid
Exide Technologies Laureldale, PA
Attorney
Hazardous material exposure – pipe & tank failure
Falling load of steel
Kemco Mobile, AL
Attorney
Crushing of man working under a load
Light hydrocarbons
Partridge-Raliegh Smith County, Mississippi
Attorney
Tank explosion and fire at oil and gas well
Tributyl phosphate, tributoxyethyl phosphate, Hydrogen sulfide, carbon monoxide
Akzo Nobel Functional Chemicals, Inc., Gallipolis Ferry, WV
Attorney
Toxic material release - Exposure to fumes while welding in a hazardous waste tank
Toluene diisocyanate (TDI)
Bayer Material Science Baytown, Texas
Attorney
Toxic material release - Runaway reaction in tank resulting in an explosion – Chemical plant
Light hydrocarbons
Pasadena Refining Systems Pasadena, Texas
Attorney
Flash fire in process sewer - Refinery
Sulfuric acid, sulfur dioxide, hydrogen sulfide
Valero Refining Houston, Texas
Attorney
Toxic material release – Release of toxic vapors from acid storage tank - Refinery
Hot paper stock/water/chlorine dioxide
MeadWestvaco Escanaba, MI
Attorney
Burns from hot chemicals in pulp bleacher
Hot water (condensate)
MEMC Pasadena, Inc. Pasadena, Texas
Attorney
Burns from hot condensate
Cumene hydroperoxide
Von Roll America – Waste Technologies, Inc.
Attorney
Runaway reaction and explosion at hazardous waste disposal cement kiln
Glacial Acetic Acid
Equistar Pasadena, Texas
Attorney
Release of hazardous materials; Chemical exposure – Chemical plant
Hot Pitch
ExxonMobil Torrance, CA
Attorney
Release of hazardous materials; Chemical exposure and burns – Refinery vacuum tower
Natural gas
Dune Energy, Inc. Bayou Couba, LA
Attorney
Physical explosion of pressure vessel in oil production field
Hot pitch
ExxonMobil
Attorney
Release of hot pitch and resulting flash fire – Refinery vacuum tower
Baytown, Texas
Attorney
Fired heater explosion – Ocean going barge
Diesel fuel
Penn Marine Barge Everglades
Attorney
Toxic material release - Pipeline rupture resulting in vapor cloud explosion – Refinery HF alkylation
Isobutane, HF
Citgo Corpus Christi, Texas
Attorney
Toxic material release - Hose rupture releasing toxic gas – Chemical plant
Silicon tetrafluoride
MEMC Pasadena, Texas
Attorney
Pipeline rupture resulting in vapor cloud explosion – Refinery Sat Gas unit
Light Hydrocarbons
Delek refining Tyler, Texas
Attorney
Pump/pressure vessel rupture resulting in vapor cloud explosion – Refinery propylene distillation
Propane/Propylene
Alon USA Refinery Big Spring, Texas
Attorney
Runaway reaction – incompatible materials explosion during distillation
Sodium hydroxide Ethylene glycol
Air Products & Chemicals Pueblo, CO
Attorney/Insurance Company
Pressure vessel explosion – Gas transmission line filter separator
Nitrogen
Kinder Morgan pump station, Smith County, MS
Attorney
72 incidents resulting in emission events and or noncompliance with permits and orders - Refinery
Volatile Organic Compounds (VOC), Hydrogen Sulfide (H2S), Sulfur Dioxide (SO2)
BP Products North America, Texas City, Texas
Texas Attorney General/TCEQ
Explosion/fire while welding on pipe/tank – Crude oil transmission line
Crude oil
Marathon, St. James, LA
Attorney
Explosion and fire from ruptured heat exchanger – Refinery hydrocracker unit
Naphtha, hydrogen
Tesoro, Anacortes, WA
Attorney
Toxic material release - Release of hot, toxic hydrocarbons from a Flexicoker Heater during maintenance - Refinery
Naphtha, hydrogen sulfide, steam
ExxonMobil, Baytown, Texas
Attorney
Toxic material release - Centrifugal compressor failure and resulting emission event – Refinery hydrocracker unit
Benzene, hydrogen, sulfur dioxide, hydrocarbons
BP Products North America, Texas City, Texas
Attorney
Fireball/Dust explosion during maintenance – Rail car maintenance facility
Steel shot abrasive blasting and paint dust
Watco Mechanical Services Hockley, Texas
Attorney
Fireball/Fire during maintenance of underground LPG storage system – LPG Storage facility
Ethane Propane
Enterprise Products Partners Mont Belvieu, Texas
Attorney
Toxic material release - Explosion and fire resulting from runaway reaction – Chemical plant
Methyl isocyanate (MIC)
Bayer Agricultural Chemicals Institute, WV
US DOJ (EPA)
Fireball while performing maintenance on Flare Drum - Refinery
Hydrocarbons
Valero Memphis, TN
Attorney
Explosion and fire in pressure vessel while performing maintenance – Chemical plant
Hydrocarbons
Chevron Phillips Chemical Port Arthur, Texas
Attorney
Toxic material release - Release of toxic vapors from storage tanks during catalyst pre-sulfiding – Refinery hydrocracker unit
Hydrogen sulfide, Methyl Mercaptan, Dimethyl Sulfide Dimethyl Disulfide Ethyl Mercaptan
BP North America Texas City, Texas
Attorney
Release of hot toxic liquid from reactor expansion joint – Chemical plant
Bisphenol A (BPA), Phenol, Hydrochloric acid
Haverhill Chemicals Haverhill, OH
Attorney
Vapor cloud explosion/fireball during pipeline pigging – Natural gas transmission line
Natural gas liquids (NGL)
Eureka Hunter Wick, WV
Attorney
Toxic material release - Release of hot, toxic liquid from cartridge filter – Chemical plant
Ammonium phosphate, Hydrogen cyanide, Ammonia
Dow Chemical/Rohm & Haas Deer Park, Texas
Attorney
Large bag of tools dropped onto head of employee working below
Hand and power tools
Chevron USA Richmond, CA
Attorney
Storage tank roof structure collapse
Construction methodology
TARSCO/Trafigura Corpus Christi, Texas
Attorney
Vapor cloud explosion – Release of hot naphtha due to vessel overflow, misdirected flow
Naphtha
International Wax, Inc. Smethport, PA
Attorney/Insurance Company
Fireball – Reactive chemical ignition during maintenance
Sodium Chlorate
Environmental Enterprises Columbus, OH
Attorney
Fireball – Hydrogen release during flare drum maintenance
Hydrogen
Marathon Petroleum Texas City, Texas
Attorney/Insurance Company
Dust explosion and fire in baghouse & ductwork
Wood sanding dust
Georgia Pacific Corrigan, Texas
Attorney
Toxic material release – Exposure to hydrogen sulfide while loading sodium hydrosulfide tank truck
Hydrogen sulfide Sodium Hydrosulfide Sodium Hydrogen Sulfide
Calumet Montana Refinery Great Falls, Montana
Attorney
Toxic material release – Exposure to hydrogen sulfide while gauging production tanks
Hydrogen Sulfide Petroleum hydrocarbons
EOG Resources Montague County, Texas
Attorney
Explosion – Internal pipeline explosion during maintenance
Crude oil
SUNOCO Logistics Nederland, Texas
Attorney
Explosion – Reactive chemical explosion in vacuum truck tank
Hydrogen Peroxide
PeroxyChem Pasadena, Texas
Attorney
Explosion and fire – Pipe failure due to Sulfidation corrosion
Light gas oil, naphtha
Chevron Richmond, CA
Attorney
Fire in Sulfur Recovery Unit during maintenance
Sulfur, Sulfur Dioxide Hydrogen Sulfide
Shell Chemical Deer Park, Texas
Attorney
Exposure to Toxic Materials at oil production facility
Hydrogen Sulfide
EOG Resources
Attorney
Fire in a Fluidized Bed Cat Cracker (FCCU) during maintenance
Wood Plastic/rubber
Marathon Oil Texas City, Texas
Attorney/Insurance Company
Steam release at boiler during maintenance
Steam
Graphic Packaging International Queen City, TX
Attorney
Vapor cloud explosion and fire in Alkylation Unit during startup/maintenance
Isobutane
ExxonMobil Baton Rouge, LA
Attorney
Dust explosion in electrical control panel at powder coating facility
Epoxy paint dust
Aegion Coating Systems Conroe, Texas
Attorney
Explosions and Fires at Chemical Plant due to pipeline rupture
1,3-Butadiene, Butadiene Popcorn Polymer and other hydrocarbons
TPC Port Neches, Texas
Attorney
Fire at Chemical Plant
Confidential
Confidential
U.S. Chemical Safety & Hazard Investigation Board
Fire and Explosion at Chemical Plant
Confidential
Confidential
Attorney
Confined Space Asphyxiation
Argon
Ferguson McMoRan Copper Mine, Morenci, AZ
Attorney
Exposure to Toxic vapors while opening pipeline
Hydrofluoric Acid
Wynnewood Refining, Wynnewood, OK
Attorney
Fire and explosion in Refinery while opening pipeline
Hydrogen
Shell Convent Refinery, Port Allen, LA
Attorney
Fire and explosion in refinery while performing maintenance on a pipeline in a refinery
Hydrogen, Naphtha, Hydrogen Sulfide
ExxonMobil refinery Baytown, Texas
Attorney
Release of toxic and asphyxiant gases causing asphyxiation and neurological damage
Hydrogen, Nitrogen, Carbon Monoxide
OXEA Chemicals Bay City, Texas
Attorney
Fire and explosion in refinery during a process upset
Naphtha
BP-Husky Refinery Oregon, Ohio
Attorney
Asphyxiation of a worker inside an inerted reactor
Nitrogen
Hunt Refining Tuscaloosa, Alabama
Attorney
Asphyxiation of a worker inside an inerted reactor
Nitrogen
HF Sinclair Refinery El Dorado, Kansas
Attorney
Asphyxiation of a worker inside a reactor containing an inert gas
Argon
CF Industries Nitrogen Donaldsonville, Louisiana
Attorney
Burns from hot condensate while modifying pipeline
Hot condensate
Clariant, Pasadena, Texas
Attorney
Acid burns in refinery Alkylation Unit
Concentrated Sulfuric Acid
Motiva, Port Arthur, Texas
Attorney
Fire, explosion and fatality due to tube failure in a furnace in the HDO unit in a refinery
Diesel and hydrogen
Marathon/TESORO Martinez, California
Attorney
Severe burns while dumping a coker unit
Coke and superheated water
Valero Norco, Louisianna
Attorney
Fatal fire due to structural failure of a hydrocarbon processing pump
Naphtha
Blanchard Refining Company (Marathon) Texas City, Texas
Attorney