Industrial Incidents Caused by Control System Failure¶
Control system failures documented by the CSB range from hardware faults in distributed control systems (DCS) and programmable logic controllers (PLC) to software logic errors and improper configuration changes. These investigations highlight how control system failures interact with operator response and how defense-in-depth is compromised when automated safeguards and human oversight fail simultaneously.
Incidents (7)¶
| Incident | Date | Location | Key Hazards |
|---|---|---|---|
| Bayer CropScience Pesticide Waste Tank Explosion | 08/28/2008 | Institute, WV | Runaway Reaction, Explosion |
| Millard Refrigerated Services Ammonia Release | 08/23/2010 | Theodore, AL | Ammonia Release, Chemical Release |
| Philadelphia Energy Solutions (PES) Refinery Fire and Explosions | 06/21/2019 | Philadelphia, PA | Chemical Release, Explosion |
| CTA Acoustics Dust Explosion and Fire | 02/20/2003 | Corbin, KY | Dust Explosion, Fire |
| Foundation Food Group Fatal Chemical Release | 01/28/2021 | Gainesville , GA | Chemical Release, Asphyxiation |
| Watson Grinding Fatal Explosion and Fire | 01/24/2020 | Houston, TX | Chemical Release, Explosion |
| Pryor Trust Fatal Gas Well Blowout and Fire | 01/22/2018 | Pittsburg County, OK | Explosion, Fire |
Common Patterns¶
Across these 7 investigations, the CSB consistently found control system failure alongside these co-occurring failure modes, industries, and hazard types:
Co-occurring failure modes: Design Deficiency · Procedural Failure · Communication Failure · Training Deficiency · Human / Operator Error
Primary industries: Food Processing, Chemical Manufacturing, Petroleum Refining
Associated hazard types: Chemical Release · Explosion · Fire · Toxic Release
Data sourced from CSB.gov public investigation reports. This site is an independent project not affiliated with the U.S. CSB.