Industrial Incidents Caused by Ignition Source Control Failure¶
Inadequate control of ignition sources — open flames, hot work without permits, non-intrinsically safe equipment in classified areas, and static discharge — provided the spark for vapor cloud and combustible dust explosions that could have been prevented. These investigations show how normalised deviation from hot-work permit requirements and inadequate electrical area classification created ignition risks in flammable atmospheres.
Incidents (26)¶
| Incident | Date | Location | Key Hazards |
|---|---|---|---|
| AL Solutions Fatal Dust Explosion | 12/09/2010 | New Cumberland, WV | Dust Explosion, Fire |
| E. I. DuPont De Nemours Co. Fatal Hotwork Explosion | 11/09/2010 | Buffalo, NY | Explosion, Fire |
| Barton Solvents Flammable Liquid Explosion and Fire | 10/29/2007 | Des Moines, IA | Fire, Explosion |
| Xcel Energy Company Hydroelectric Tunnel Fire | 10/02/2007 | Georgetown, CO | Fire, Flash Fire |
| Evergreen Packaging Paper Mill - Fire During Hot Work | 09/21/2020 | Canton, NC | Fire |
| Packaging Corporation Storage Tank Explosion | 07/29/2008 | Tomahawk, WI | Explosion, Fire |
| Barton Solvents Explosions and Fire | 07/17/2007 | Valley Center, KS | Explosion, Fire |
| Motiva Enterprises Sulfuric Acid Tank Explosion | 07/17/2001 | Delaware City, DE | Explosion, Fire |
| Praxair Flammable Gas Cylinder Fire | 06/24/2005 | St. Louis, MO | Fire, Explosion |
| ConAgra Natural Gas Explosion and Ammonia Release | 06/09/2009 | Garner, NC | Explosion, Ammonia Release |
| Partridge Raleigh Oilfield Explosion and Fire | 06/05/2006 | Raleigh, MS | Explosion, Fire |
| Didion Milling Company Explosion and Fire | 05/31/2017 | Cambria, WI | Dust Explosion, Explosion |
| Third Coast Industries Petroleum Products Facility Fire | 05/01/2002 | Brazoria County, TX | Fire, Pool Fire |
| Husky Energy Superior Refinery Explosion and Fire | 04/26/2018 | Superior, WI | Explosion, Fire |
| Donaldson Enterprises, Inc. Fatal Fireworks Disassembly Explosion and Fire | 04/08/2011 | Waipahu, HI | Explosion, Fire |
| Tosco Avon Refinery Petroleum Naphtha Fire | 02/23/1999 | Martinez, CA | Fire, Flash Fire |
| Packaging Corporation of America Hot Work Explosion | 02/08/2017 | Deridder, LA | Explosion, Fire |
| Kleen Energy Natural Gas Explosion | 02/07/2010 | Middletown, CT | Explosion, Chemical Release |
| Imperial Sugar Company Dust Explosion and Fire | 02/07/2008 | Port Wentworth, GA | Dust Explosion, Explosion |
| Bethlehem Steel Corporation Gas Condensate Fire | 02/02/2001 | Chesterton, IN | Fire, Explosion |
| Hoeganaes Corporation Fatal Flash Fires | 01/31/2011 | Gallatin, TN | Flash Fire, Dust Explosion |
| Wendland 1H Well Fatal Explosion | 01/29/2020 | Burleson County , TX | Explosion, Fire |
| West Pharmaceutical Services Dust Explosion and Fire | 01/29/2003 | Kinston, NC | Dust Explosion, Explosion |
| BLSR Operating Ltd. Vapor Cloud Fire | 01/13/2003 | Rosharon, TX | Vapor Cloud Explosion, Flash Fire |
| Bethune Point Wastewater Plant Explosion | 01/11/2006 | Daytona Beach, FL | Explosion, Fire |
| Catalyst Systems Inc. Reactive Chemical Explosion | 01/02/2003 | Gnadenhutten, OH | Explosion, Fire |
Common Patterns¶
Across these 26 investigations, the CSB consistently found ignition source control failure alongside these co-occurring failure modes, industries, and hazard types:
Co-occurring failure modes: Procedural Failure · Design Deficiency · Training Deficiency · Contractor Management Failure · Communication Failure
Primary industries: Chemical Manufacturing, Transportation, Petroleum Refining
Associated hazard types: Fire · Explosion · Chemical Release · Flash Fire
Data sourced from CSB.gov public investigation reports. This site is an independent project not affiliated with the U.S. CSB.