Gas Detector Failures and Toxic Release Incidents¶
Fixed gas detection systems are critical early-warning safeguards in facilities handling toxic or flammable gases; sensor drift, poor placement, or inadequate maintenance have caused detectors to fail when needed most. These investigations show how detector deficiencies contributed to delayed response and harm.
28 CSB investigations in this database involve gas detector as a primary or contributing equipment factor, spanning 1998–2024.
Gas Detector Failures and Toxic Release Incidents (28)¶
| Incident | Date | Industry | Key Hazard |
|---|---|---|---|
| Environmental Enterprises Hydrogen Sulfide Release | 12/11/2002 | Wastewater Treatment | Hydrogen Sulfide Release, Toxic Release |
| DuPont La Porte Facility Toxic Chemical Release | 11/15/2014 | Chemical Manufacturing | Toxic Release, Chemical Release |
| E. I. DuPont De Nemours Co. Fatal Hotwork Explosion | 11/09/2010 | Chemical Manufacturing | Explosion, Fire |
| Aghorn Operating Inc. Waterflood Station Hydrogen Sulfide Release | 10/26/2019 | Oil And Gas Production | Hydrogen Sulfide Release, Toxic Release |
| PEMEX Deer Park Chemical Release | 10/10/2024 | Petroleum Refining | Hydrogen Sulfide Release, Toxic Release |
| BP - Husky Oregon Chemical Release and Fire | 09/20/2022 | Petroleum Refining | Chemical Release, Fire |
| Bayer CropScience Pesticide Waste Tank Explosion | 08/28/2008 | Chemical Manufacturing | Runaway Reaction, Explosion |
| Millard Refrigerated Services Ammonia Release | 08/23/2010 | Food Processing | Ammonia Release, Chemical Release |
| Sterigenics Ethylene Oxide Explosion | 08/19/2004 | Chemical Manufacturing | Explosion, Fire |
| DPC Enterprises Festus Chlorine Release | 08/14/2002 | Chemical Manufacturing | Chemical Release, Toxic Release |
| Sunoco Logistics Partners Flash Fire | 08/12/2016 | Transportation | Flash Fire, Explosion |
| Cuisine Solutions Ammonia Release | 07/31/2024 | Food Processing | Ammonia Release, Toxic Release |
| Packaging Corporation Storage Tank Explosion | 07/29/2008 | Paper And Pulp | Explosion, Fire |
| Honeywell Chemical Incidents | 07/20/2003 | Chemical Manufacturing | Chemical Release, Toxic Release |
| Motiva Enterprises Sulfuric Acid Tank Explosion | 07/17/2001 | Petroleum Refining | Explosion, Fire |
| Praxair Flammable Gas Cylinder Fire | 06/24/2005 | Chemical Manufacturing | Fire, Explosion |
| ConAgra Natural Gas Explosion and Ammonia Release | 06/09/2009 | Food Processing | Explosion, Ammonia Release |
| Partridge Raleigh Oilfield Explosion and Fire | 06/05/2006 | Oil And Gas Production | Explosion, Fire |
| AB Specialty Silicones, LLC | 05/03/2019 | Chemical Manufacturing | Chemical Release, Explosion |
| Formosa Plastics Vinyl Chloride Explosion | 04/23/2004 | Chemical Manufacturing | Explosion, Fire |
| MFG Chemical Inc. Toxic Gas Release | 04/12/2004 | Chemical Manufacturing | Runaway Reaction, Toxic Release |
| Yenkin-Majestic Resin Plant Vapor Cloud Explosion and Fire | 04/08/2021 | Chemical Manufacturing | Vapor Cloud Explosion, Explosion |
| Intercontinental Terminals Company (ITC) Tank Fire | 03/17/2019 | Petroleum Refining | Fire, Pool Fire |
| ExxonMobil Torrance Refinery Explosion | 02/18/2015 | Petroleum Refining | Explosion, Fire |
| Packaging Corporation of America Hot Work Explosion | 02/08/2017 | Paper And Pulp | Explosion, Fire |
| Foundation Food Group Fatal Chemical Release | 01/28/2021 | Food Processing | Chemical Release, Asphyxiation |
| Watson Grinding Fatal Explosion and Fire | 01/24/2020 | Metals | Chemical Release, Explosion |
| DuPont Belle Toxic Chemical Releases | 01/23/2010 | Chemical Manufacturing | Toxic Release, Chemical Release |
Related Hazard Types¶
Chemical Release · Fire · Explosion · Toxic Release · Flash Fire
Related Equipment¶
Valve Failures in Process Plant Incidents · Pipeline Ruptures, Leaks, and Fires · Storage Tank Fires and Explosions · Interlock Failures in Process Safety Incidents · Pressure Vessel Explosions and Failures · Pump Failures and Process Safety Incidents
Data sourced from CSB.gov public investigation reports. This site is an independent project not affiliated with the U.S. CSB.