Industrial Incidents Caused by Training Deficiency¶
Training deficiencies identified by the CSB include inadequate initial training, failure to train on abnormal conditions (not just routine operations), and no refresher training for infrequent but high-consequence tasks. These investigations show how workers placed in novel or emergency situations without adequate preparation made decisions that contributed to incidents.
73 investigations
Industries: Chemical Manufacturing, Metals, Plastics
Years: 1998–2024
Incidents (73)¶
| Incident | Date | Location | Key Hazards |
|---|---|---|---|
| T2 Laboratories Inc. Reactive Chemical Explosion | 12/19/2007 | Jacksonville, FL | Runaway Reaction, Thermal Runaway |
| Environmental Enterprises Hydrogen Sulfide Release | 12/11/2002 | Cincinnati, OH | Hydrogen Sulfide Release, Toxic Release |
| AL Solutions Fatal Dust Explosion | 12/09/2010 | New Cumberland, WV | Dust Explosion, Fire |
| Marcus Oil and Chemical Tank Explosion | 12/03/2004 | Houston, TX | Explosion, Fire |
| ExxonMobil Baton Rouge Refinery Chemical Release and Fire | 11/22/2016 | Baton Rouge, LA | Chemical Release, Fire |
| Marathon Martinez Renewable Fuels Fire | 11/19/2023 | Martinez, CA | Fire, Chemical Release |
| DPC Enterprises Glendale Chlorine Release | 11/17/2003 | Glendale, AZ | Toxic Release, Chemical Release |
| E. I. DuPont De Nemours Co. Fatal Hotwork Explosion | 11/09/2010 | Buffalo, NY | Explosion, Fire |
| Valero Delaware City Refinery Asphyxiation Incident | 11/05/2005 | Delaware City, DE | Asphyxiation |
| Hayes Lemmerz Dust Explosions and Fire | 10/29/2003 | Huntington, IN | Dust Explosion, Fire |
| Aghorn Operating Inc. Waterflood Station Hydrogen Sulfide Release | 10/26/2019 | Odessa, TX | Hydrogen Sulfide Release, Toxic Release |
| Caribbean Petroleum Corporation (CAPECO) Refinery Tank Explosion and Fire | 10/23/2009 | Bayamón, PR | Chemical Release, Explosion |
| First Chemical Corp. Reactive Chemical Explosion | 10/13/2002 | Pascgoula, MS | Runaway Reaction, Explosion |
| INDSPEC Chemical Corporation Oleum Release | 10/11/2008 | Petrolia, PA | Chemical Release, Toxic Release |
| US Ink Fire | 10/09/2012 | East Rutherford , NJ | Dust Explosion, Flash Fire |
| 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 |
| BP - Husky Oregon Chemical Release and Fire | 09/20/2022 | Oregon, OH | Chemical Release, Fire |
| Bayer CropScience Pesticide Waste Tank Explosion | 08/28/2008 | Institute, WV | Runaway Reaction, Explosion |
| Bio-Lab Lake Charles Chemical Fire and Release | 08/27/2020 | Lake Charles, LA | Runaway Reaction, Toxic Release |
| Sterigenics Ethylene Oxide Explosion | 08/19/2004 | Ontario, CA | Explosion, Fire |
| DPC Enterprises Festus Chlorine Release | 08/14/2002 | Festus, MO | Chemical Release, Toxic Release |
| Cuisine Solutions Ammonia Release | 07/31/2024 | Sterling, VA | Ammonia Release, Toxic Release |
| Packaging Corporation Storage Tank Explosion | 07/29/2008 | Tomahawk, WI | Explosion, Fire |
| LyondellBasell La Porte Fatal Chemical Release | 07/27/2021 | La Porte, TX | Chemical Release, Toxic Release |
| Horsehead Holding Company Fatal Explosion and Fire | 07/22/2010 | Monaca, PA | Explosion, Fire |
| Honeywell Chemical Incidents | 07/20/2003 | Baton Rouge, LA | Chemical Release, Toxic Release |
| Universal Form Clamp Co. Explosion and Fire | 06/14/2006 | Bellwood, IL | Vapor Cloud Explosion, Fire |
| Goodyear Heat Exchanger Rupture | 06/11/2008 | Houston, TX | Overpressure, Chemical Release |
| 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 |
| TS USA Molten Salt Eruption | 05/30/2024 | — | Explosion, Overpressure |
| Midland Resource Recovery Explosion | 05/24/2017 | Barbour County, WV | Explosion, Runaway Reaction |
| Kuraray Pasadena Release and Fire | 05/19/2018 | Pasadena, TX | Chemical Release, Fire |
| Veolia Environmental Services Flammable Vapor Explosion and Fire | 05/04/2009 | West Carrollton, OH | Explosion, Fire |
| AB Specialty Silicones, LLC | 05/03/2019 | Waukegan, IL | Chemical Release, Explosion |
| Husky Energy Superior Refinery Explosion and Fire | 04/26/2018 | Superior, WI | Explosion, Fire |
| Kaltech Industries Waste Mixing Explosion | 04/25/2002 | New York , NY | Runaway Reaction, Explosion |
| Formosa Plastics Vinyl Chloride Explosion | 04/23/2004 | Illiopolis, IL | Explosion, Fire |
| West Fertilizer Explosion and Fire | 04/17/2013 | West, TX | Fire, Explosion |
| MFG Chemical Inc. Toxic Gas Release | 04/12/2004 | Dalton, GA | Runaway Reaction, Toxic Release |
| 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 |
| Donaldson Enterprises, Inc. Fatal Fireworks Disassembly Explosion and Fire | 04/08/2011 | Waipahu, HI | Explosion, Fire |
| Morton International Inc. Runaway Chemical Reaction | 04/08/1998 | Patterson, NJ | Runaway Reaction, Thermal Runaway |
| KMCO LLC Fatal Fire and Explosion | 04/02/2019 | Crosby, TX | Vapor Cloud Explosion, Flash Fire |
| Union Carbide Corp. Nitrogen Asphyxiation Incident | 03/27/1998 | Hahnville, LA | Asphyxiation, Toxic Release |
| BP America (Texas City) Refinery Explosion | 03/23/2005 | Texas City, TX | Explosion, Fire |
| Carbide Industries Fire and Explosion | 03/21/2011 | Louisville, KY | Explosion, Overpressure |
| BP Amoco Thermal Decomposition Incident | 03/13/2001 | Augusta, GA | Chemical Release, Explosion |
| Sonat Exploration Co. Catastrophic Vessel Overpressurization | 03/04/1998 | Pitkin, LA | Overpressure, Fire |
| CTA Acoustics Dust Explosion and Fire | 02/20/2003 | Corbin, KY | Dust Explosion, 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 |
| Technic Inc. Ventilation System Explosion | 02/07/2003 | Cranston, RI | Explosion, Fire |
| 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 |
| Synthron Chemical Explosion | 01/31/2006 | Morganton, NC | Runaway Reaction, Vapor Cloud Explosion |
| Little General Store Propane Explosion | 01/30/2007 | Ghent, WV | Chemical Release, Vapor Cloud Explosion |
| West Pharmaceutical Services Dust Explosion and Fire | 01/29/2003 | Kinston, NC | Dust Explosion, Explosion |
| 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 |
| DuPont Belle Toxic Chemical Releases | 01/23/2010 | Belle, WV | Toxic Release, Chemical Release |
| Pryor Trust Fatal Gas Well Blowout and Fire | 01/22/2018 | Pittsburg County, OK | Explosion, Fire |
| Georgia-Pacific Corp. Hydrogen Sulfide Poisoning | 01/16/2002 | Pennington, AL | Hydrogen Sulfide Release, Toxic Release |
| 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 |
| Texas Tech University Chemistry Lab Explosion | 01/07/2010 | Lubbock, TX | Explosion, Runaway Reaction |
| Sierra Chemical Co. High Explosives Accident | 01/07/1998 | Mustang, NV | Explosion, Fire |
| Catalyst Systems Inc. Reactive Chemical Explosion | 01/02/2003 | Gnadenhutten, OH | Explosion, Fire |
Common Patterns¶
Across these 73 investigations, the CSB consistently found training deficiency alongside these co-occurring failure modes, industries, and hazard types:
Co-occurring failure modes: Procedural Failure · Design Deficiency · Communication Failure · Management of Change Failure · Human / Operator Error
Primary industries: Chemical Manufacturing, Metals, Plastics
Associated hazard types: Fire · Explosion · Chemical Release · Overpressure
Data sourced from CSB.gov public investigation reports. This site is an independent project not affiliated with the U.S. CSB.