Relief Valve Failures and Overpressure Events¶
Relief valves are the last line of defense against overpressure, and their failure to open, failure to reseat, or undersizing have directly contributed to vessel ruptures and toxic releases. These investigations illustrate how relief system deficiencies compound in major accidents.
22 CSB investigations in this database involve relief valve as a primary or contributing equipment factor, spanning 1998–2024.
Relief Valve Failures and Overpressure Events (22)¶
| Incident | Date | Industry | Key Hazard |
|---|---|---|---|
| T2 Laboratories Inc. Reactive Chemical Explosion | 12/19/2007 | Chemical Manufacturing | Runaway Reaction, Thermal Runaway |
| Optima Belle Explosion and Fire | 12/08/2020 | Chemical Manufacturing | Explosion, Fire |
| NDK Crystal Inc. Explosion with Offsite Fatality | 12/07/2009 | Chemical Manufacturing | Explosion, Overpressure |
| TPC Port Neches Explosions and Fire | 11/27/2019 | Chemical Manufacturing | Chemical Release, Explosion |
| First Chemical Corp. Reactive Chemical Explosion | 10/13/2002 | Chemical Manufacturing | Runaway Reaction, Explosion |
| Formosa Plastics Propylene Explosion | 10/06/2005 | Chemical Manufacturing | Chemical Release, Explosion |
| 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 |
| Cuisine Solutions Ammonia Release | 07/31/2024 | Food Processing | Ammonia Release, Toxic Release |
| Dow Louisiana Operations Explosions | 07/14/2023 | Chemical Manufacturing | Explosion, Fire |
| Praxair Flammable Gas Cylinder Fire | 06/24/2005 | Chemical Manufacturing | Fire, Explosion |
| Williams Olefins Plant Explosion and Fire | 06/13/2013 | Chemical Manufacturing | Bleve, Chemical Release |
| Goodyear Heat Exchanger Rupture | 06/11/2008 | Chemical Manufacturing | Overpressure, Chemical Release |
| Kuraray Pasadena Release and Fire | 05/19/2018 | Chemical Manufacturing | Chemical Release, Fire |
| MFG Chemical Inc. Toxic Gas Release | 04/12/2004 | Chemical Manufacturing | Runaway Reaction, Toxic Release |
| Herrig Brothers Farm Propane Tank Explosion | 04/09/1998 | Agriculture | Bleve, Explosion |
| Morton International Inc. Runaway Chemical Reaction | 04/08/1998 | Chemical Manufacturing | Runaway Reaction, Thermal Runaway |
| BP America (Texas City) Refinery Explosion | 03/23/2005 | Petroleum Refining | Explosion, Fire |
| BP Amoco Thermal Decomposition Incident | 03/13/2001 | Chemical Manufacturing | Chemical Release, Explosion |
| Packaging Corporation of America Hot Work Explosion | 02/08/2017 | Paper And Pulp | Explosion, Fire |
| Synthron Chemical Explosion | 01/31/2006 | Chemical Manufacturing | Runaway Reaction, Vapor Cloud Explosion |
| Little General Store Propane Explosion | 01/30/2007 | Transportation | Chemical Release, Vapor Cloud Explosion |
Related Hazard Types¶
Chemical Release · Fire · Explosion · Overpressure · Structural Failure
Related Equipment¶
Valve Failures in Process Plant Incidents · Pressure Vessel Explosions and Failures · Heat Exchanger Failures and Fires · Reactor Explosions and Runaway Reactions · Pipeline Ruptures, Leaks, and Fires · 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.