Industrial Incidents Caused by Inspection Failure¶
Inspection failures — missed defects during routine inspection, inadequate inspection frequency, or programs that did not cover the actual failure mechanism — allowed equipment degradation to reach failure while owners believed the asset was sound. These investigations document how corrosion, cracking, and erosion advanced to loss of containment because the affected areas were either not inspected or not inspected correctly.
Incidents (35)¶
| Incident | Date | Location | Key Hazards |
|---|---|---|---|
| AL Solutions Fatal Dust Explosion | 12/09/2010 | New Cumberland, WV | Dust Explosion, Fire |
| NDK Crystal Inc. Explosion with Offsite Fatality | 12/07/2009 | Belvidere, IL | Explosion, Overpressure |
| Marcus Oil and Chemical Tank Explosion | 12/03/2004 | Houston, TX | Explosion, Fire |
| TPC Port Neches Explosions and Fire | 11/27/2019 | Port Neches, TX | Chemical Release, Explosion |
| CAI / Arnel Chemical Plant Explosion | 11/22/2006 | Danvers, MA | Explosion, Fire |
| Allied Terminals Fertilizer Tank Collapse | 11/11/2008 | Chesapeake, VA | Chemical Release, Structural Failure |
| First Chemical Corp. Reactive Chemical Explosion | 10/13/2002 | Pascgoula, MS | Runaway Reaction, Explosion |
| Bayer CropScience Pesticide Waste Tank Explosion | 08/28/2008 | Institute, WV | Runaway Reaction, Explosion |
| DPC Enterprises Festus Chlorine Release | 08/14/2002 | Festus, MO | Chemical Release, Toxic Release |
| Chevron Richmond Refinery Pipe Rupture and Fire | 08/06/2012 | Richmond, CA | Chemical Release, Fire |
| Honeywell Chemical Incidents | 07/20/2003 | Baton Rouge, LA | Chemical Release, Toxic Release |
| Motiva Enterprises Sulfuric Acid Tank Explosion | 07/17/2001 | Delaware City, DE | Explosion, Fire |
| Dow Louisiana Operations Explosions | 07/14/2023 | Plaquemine, LA | Explosion, Fire |
| Philadelphia Energy Solutions (PES) Refinery Fire and Explosions | 06/21/2019 | Philadelphia, PA | Chemical Release, Explosion |
| Didion Milling Company Explosion and Fire | 05/31/2017 | Cambria, WI | Dust Explosion, Explosion |
| Veolia Environmental Services Flammable Vapor Explosion and Fire | 05/04/2009 | West Carrollton, OH | Explosion, Fire |
| Kaltech Industries Waste Mixing Explosion | 04/25/2002 | New York , NY | Runaway Reaction, Explosion |
| Macondo Blowout and Explosion | 04/20/2010 | — | Explosion, Fire |
| D.D. Williamson & Co. Catastrophic Vessel Failure | 04/11/2003 | Louisville, KY | Overpressure, Explosion |
| Herrig Brothers Farm Propane Tank Explosion | 04/09/1998 | Albert City, IA | Bleve, Explosion |
| Yenkin-Majestic Resin Plant Vapor Cloud Explosion and Fire | 04/08/2021 | Columbus, OH | Vapor Cloud Explosion, Explosion |
| Loy Lange Box Company Pressure Vessel Explosion | 04/03/2017 | St. Louis , MO | Explosion, Overpressure |
| Tesoro Anacortes Refinery Fatal Explosion and Fire | 04/02/2010 | Anacortes, WA | Explosion, Fire |
| Carbide Industries Fire and Explosion | 03/21/2011 | Louisville, KY | Explosion, Overpressure |
| ExxonMobil Torrance Refinery Explosion | 02/18/2015 | Torrance, CA | Explosion, Fire |
| Valero McKee Refinery Propane Fire | 02/16/2007 | Sunray, TX | Fire, Flash Fire |
| Tesoro Martinez Sulfuric Acid Spill | 02/12/2014 | Martinez, CA | Chemical Release, Toxic Release |
| Technic Inc. Ventilation System Explosion | 02/07/2003 | Cranston, RI | Explosion, Fire |
| Hoeganaes Corporation Fatal Flash Fires | 01/31/2011 | Gallatin, TN | Flash Fire, Dust Explosion |
| Little General Store Propane Explosion | 01/30/2007 | Ghent, WV | Chemical Release, Vapor Cloud Explosion |
| Honeywell Geismar Chlorine and Hydrogen Fluoride Releases | 01/23/2023 | Geismar, LA | Chemical Release, Explosion |
| Silver Eagle Refinery Flash Fire and Explosion and Catastrophic Pipe Explosion | 01/12/2009 | Woods Cross, UT | Flash Fire, Explosion |
| Bethune Point Wastewater Plant Explosion | 01/11/2006 | Daytona Beach, FL | Explosion, Fire |
| Freedom Industries Chemical Release | 01/09/2014 | Charleston, WV | Chemical Release, Toxic Release |
| Sierra Chemical Co. High Explosives Accident | 01/07/1998 | Mustang, NV | Explosion, Fire |
Common Patterns¶
Across these 35 investigations, the CSB consistently found inspection failure alongside these co-occurring failure modes, industries, and hazard types:
Co-occurring failure modes: Design Deficiency · Procedural Failure · Training Deficiency · Management of Change Failure · Human / Operator Error
Primary industries: Chemical Manufacturing, Petroleum Refining, Metals
Associated hazard types: Explosion · Chemical Release · Fire · Structural Failure
Data sourced from CSB.gov public investigation reports. This site is an independent project not affiliated with the U.S. CSB.