Valve Failures in Process Plant Incidents¶
Isolation and control valves are critical to emergency shutdown and normal process control; their failure — whether mechanical, manual, or software-driven — has contributed to releases and escalation in numerous incidents. These cases show how valve failures interact with other systemic and human factors.
64 CSB investigations in this database involve valve as a primary or contributing equipment factor, spanning 1998–2024.
Valve Failures in Process Plant Incidents (64)¶
| 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 |
| Marcus Oil and Chemical Tank Explosion | 12/03/2004 | Chemical Manufacturing | Explosion, Fire |
| Delaware City Refining Company | 11/29/2015 | Petroleum Refining | Flash Fire, Fire |
| TPC Port Neches Explosions and Fire | 11/27/2019 | Chemical Manufacturing | Chemical Release, Explosion |
| ExxonMobil Baton Rouge Refinery Chemical Release and Fire | 11/22/2016 | Petroleum Refining | Chemical Release, Fire |
| CAI / Arnel Chemical Plant Explosion | 11/22/2006 | Chemical Manufacturing | Explosion, Fire |
| Marathon Martinez Renewable Fuels Fire | 11/19/2023 | Petroleum Refining | Fire, Chemical Release |
| DPC Enterprises Glendale Chlorine Release | 11/17/2003 | Chemical Manufacturing | Toxic Release, Chemical 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 |
| Valero Delaware City Refinery Asphyxiation Incident | 11/05/2005 | Petroleum Refining | Asphyxiation |
| Barton Solvents Flammable Liquid Explosion and Fire | 10/29/2007 | Chemical Manufacturing | Fire, Explosion |
| Aghorn Operating Inc. Waterflood Station Hydrogen Sulfide Release | 10/26/2019 | Oil And Gas Production | Hydrogen Sulfide Release, Toxic Release |
| Caribbean Petroleum Corporation (CAPECO) Refinery Tank Explosion and Fire | 10/23/2009 | Petroleum Refining | Chemical Release, Explosion |
| First Chemical Corp. Reactive Chemical Explosion | 10/13/2002 | Chemical Manufacturing | Runaway Reaction, Explosion |
| 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 |
| Isotec/Sigma Aldrich Nitric Oxide Explosion | 09/21/2003 | Chemical Manufacturing | Explosion, Chemical 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 |
| DPC Enterprises Festus Chlorine Release | 08/14/2002 | Chemical Manufacturing | Chemical Release, Toxic Release |
| Cuisine Solutions Ammonia Release | 07/31/2024 | Food Processing | Ammonia Release, Toxic Release |
| LyondellBasell La Porte Fatal Chemical Release | 07/27/2021 | Chemical Manufacturing | Chemical Release, Toxic Release |
| Horsehead Holding Company Fatal Explosion and Fire | 07/22/2010 | Metals | Explosion, Fire |
| Honeywell Chemical Incidents | 07/20/2003 | Chemical Manufacturing | Chemical Release, Toxic Release |
| CITGO Refinery Hydrofluoric Acid Release and Fire | 07/19/2009 | Petroleum Refining | Fire, Chemical Release |
| Barton Solvents Explosions and Fire | 07/17/2007 | Chemical Manufacturing | Explosion, Fire |
| Dow Louisiana Operations Explosions | 07/14/2023 | Chemical Manufacturing | Explosion, Fire |
| Philadelphia Energy Solutions (PES) Refinery Fire and Explosions | 06/21/2019 | Petroleum Refining | Chemical Release, 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 |
| ConAgra Natural Gas Explosion and Ammonia Release | 06/09/2009 | Food Processing | Explosion, Ammonia Release |
| Midland Resource Recovery Explosion | 05/24/2017 | Chemical Manufacturing | Explosion, Runaway Reaction |
| Kuraray Pasadena Release and Fire | 05/19/2018 | Chemical Manufacturing | Chemical Release, Fire |
| Veolia Environmental Services Flammable Vapor Explosion and Fire | 05/04/2009 | Chemical Manufacturing | Explosion, Fire |
| Husky Energy Superior Refinery Explosion and Fire | 04/26/2018 | Petroleum Refining | Explosion, Fire |
| Formosa Plastics Vinyl Chloride Explosion | 04/23/2004 | Chemical Manufacturing | Explosion, Fire |
| Macondo Blowout and Explosion | 04/20/2010 | Oil And Gas Production | Explosion, Fire |
| D.D. Williamson & Co. Catastrophic Vessel Failure | 04/11/2003 | Food Processing | Overpressure, Explosion |
| Herrig Brothers Farm Propane Tank Explosion | 04/09/1998 | Agriculture | Bleve, Explosion |
| Giant Industries Refinery Explosions and Fire | 04/08/2004 | Petroleum Refining | Chemical Release, Explosion |
| Loy Lange Box Company Pressure Vessel Explosion | 04/03/2017 | Paper And Pulp | Explosion, Overpressure |
| KMCO LLC Fatal Fire and Explosion | 04/02/2019 | Chemical Manufacturing | Vapor Cloud Explosion, Flash Fire |
| Tesoro Anacortes Refinery Fatal Explosion and Fire | 04/02/2010 | Petroleum Refining | Explosion, Fire |
| Union Carbide Corp. Nitrogen Asphyxiation Incident | 03/27/1998 | Chemical Manufacturing | Asphyxiation, Toxic Release |
| Intercontinental Terminals Company (ITC) Tank Fire | 03/17/2019 | Petroleum Refining | Fire, Pool Fire |
| BP Amoco Thermal Decomposition Incident | 03/13/2001 | Chemical Manufacturing | Chemical Release, Explosion |
| Sonat Exploration Co. Catastrophic Vessel Overpressurization | 03/04/1998 | Oil And Gas Production | Overpressure, Fire |
| Tosco Avon Refinery Petroleum Naphtha Fire | 02/23/1999 | Petroleum Refining | Fire, Flash Fire |
| ExxonMobil Torrance Refinery Explosion | 02/18/2015 | Petroleum Refining | Explosion, Fire |
| Valero McKee Refinery Propane Fire | 02/16/2007 | Petroleum Refining | Fire, Flash Fire |
| Tesoro Martinez Sulfuric Acid Spill | 02/12/2014 | Petroleum Refining | Chemical Release, Toxic Release |
| Bethlehem Steel Corporation Gas Condensate Fire | 02/02/2001 | Metals | Fire, Explosion |
| Little General Store Propane Explosion | 01/30/2007 | Transportation | Chemical Release, Vapor Cloud Explosion |
| Wendland 1H Well Fatal Explosion | 01/29/2020 | Oil And Gas Production | 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 |
| Pryor Trust Fatal Gas Well Blowout and Fire | 01/22/2018 | Oil And Gas Production | Explosion, Fire |
| Georgia-Pacific Corp. Hydrogen Sulfide Poisoning | 01/16/2002 | Paper And Pulp | Hydrogen Sulfide Release, Toxic Release |
| BLSR Operating Ltd. Vapor Cloud Fire | 01/13/2003 | Oil And Gas Production | Vapor Cloud Explosion, Flash Fire |
| Catalyst Systems Inc. Reactive Chemical Explosion | 01/02/2003 | Chemical Manufacturing | Explosion, Fire |
Related Hazard Types¶
Chemical Release · Fire · Explosion · Overpressure · Toxic Release
Related Equipment¶
Pipeline Ruptures, Leaks, and Fires · Pump Failures and Process Safety Incidents · Storage Tank Fires and Explosions · Pressure Vessel Explosions and Failures · Gas Detector Failures and Toxic Release Incidents · Relief Valve Failures and Overpressure Events
Data sourced from CSB.gov public investigation reports. This site is an independent project not affiliated with the U.S. CSB.