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Flare System Failures and Incidents

Flare systems manage emergency and routine releases of flammable and toxic gases; failures in flare header design, knockout drums, or operating procedures have contributed to fires and explosions. These CSB investigations identify the specific failure modes and recommended corrective actions.

10 CSB investigations in this database involve flare as a primary or contributing equipment factor, spanning 1998–2024.

Flare System Failures and Incidents (10)

Incident Date Industry Key Hazard
PEMEX Deer Park Chemical Release 10/10/2024 Petroleum Refining Hydrogen Sulfide Release, Toxic Release
Formosa Plastics Propylene Explosion 10/06/2005 Chemical Manufacturing Chemical Release, Explosion
Bayer CropScience Pesticide Waste Tank Explosion 08/28/2008 Chemical Manufacturing Runaway Reaction, Explosion
Enterprise Pascagoula Gas Plant Explosion and Fire 06/27/2016 Oil And Gas Production Chemical Release, Explosion
Kuraray Pasadena Release and Fire 05/19/2018 Chemical Manufacturing Chemical Release, Fire
Husky Energy Superior Refinery Explosion and Fire 04/26/2018 Petroleum Refining Explosion, Fire
Giant Industries Refinery Explosions and Fire 04/08/2004 Petroleum Refining Chemical Release, Explosion
Sonat Exploration Co. Catastrophic Vessel Overpressurization 03/04/1998 Oil And Gas Production Overpressure, Fire
Pryor Trust Fatal Gas Well Blowout and Fire 01/22/2018 Oil And Gas Production Explosion, Fire
Bethune Point Wastewater Plant Explosion 01/11/2006 Wastewater Treatment Explosion, Fire

Chemical Release · Fire · Explosion · Overpressure · Structural Failure

Valve Failures in Process Plant Incidents · Pipeline Ruptures, Leaks, and Fires · Pump Failures and Process Safety Incidents · Heat Exchanger Failures and Fires · Relief Valve Failures and Overpressure Events · Pressure Vessel Explosions and Failures

Data sourced from CSB.gov public investigation reports. This site is an independent project not affiliated with the U.S. CSB.