Summary of Unsafe condition, accident & fire Reports
This is a summary of pressure equipment unsafe conditions, accidents and fires that have been reported to and investigated by ABSA. This information is provided to make people aware of the general nature of pressure equipment unsafe conditions, accidents and fires. The intent is to heighten the awareness of the general public to the hazards of pressure equipment in an effort to prevent injury.
Note: “Loss of Containment” as used in this report refers to the loss of any amount of process fluid from the pressure equipment.
| Date Reported | Injuries | Fatalities | Description | Loss of Containment |
|---|---|---|---|---|
| 2019-10-01 | 0 | 0 | A pinhole leak was discovered coming from a |||tee||| on the steam side of the low water cut-off column of a power boiler. | Yes |
| 2019-10-01 | 0 | 0 | Steam was found to be leaking from the gauge glass column of a power boiler. Vibration is suspected to be the cause of the leak. | Yes |
| 2019-10-01 | 0 | 0 | Steam was found to be leaking from the orifice flange on a boiler feedwater line. | Yes |
| 2019-09-30 | 0 | 0 | A watertube was found to be leaking in a hot water heating boiler. | Yes |
| 2019-09-27 | 0 | 0 | Vibration caused a pressure indicator to unscrew, resulting in a release of gas which in turn ignited. | Yes |
| 2019-09-24 | 0 | 0 | Cracked welds were discoverd on the drain nozzle of a compressor bottle. | Yes |
| 2019-09-23 | 0 | 0 | A process train was overpressured due to a process excursion and blocked-in PSV. Loss of containment ocurred due to gasket failure. | Yes |
| 2019-09-23 | 0 | 0 | A through wall crack was discovered at the firetube-to-tubesheet weld of a power boiler. | Yes |
| 2019-09-20 | 0 | 0 | A heat exchanger was found to be leaking. Upon investigation, the source of the leak was determined to be a faulty gasket. | Yes |
| 2019-09-04 | 0 | 0 | A 2 inch fuel gas piping line was found to be leaking due to external corrosion. | Yes |
| 2019-09-04 | 0 | 0 | During maintenance, a small fire started in a vessel. The fire is believed to have been caused by iron sulphides (in scale) reacting with oxygen. | No |
| 2019-09-03 | 0 | 0 | Pinhole leak in Thermal Fluid Heater coil caused furnace to trip on an over temperature condition. It was concluded that external abrasion between refractory and the tube caused the leak. | Yes |
| 2019-08-27 | 0 | 0 | Process fluid was found to be leaking from the weep hole of a manway repad on a pressure vessel. | Yes |
| 2019-08-22 | 0 | 0 | A pump seal failure caused an ammonia leak at a food processing facility. | Yes |
| 2019-08-06 | 0 | 0 | An H2S alarm and compressor shutdown was caused by a cracked nipple from the second stage scrubber of the compressor. The cracked nipple was found to be a result of fatigue due to vibration. | Yes |
| 2019-08-06 | 0 | 0 | A pinhole was found on the flange weld of a separator. The internal coating had failed, causing preferential corrosion at that particular location. | Yes |
| 2019-08-06 | 0 | 0 | A through wall crack was discovered on a vessel at a 24 inch nozzle weld. The crack was a result of fatigue due to vibration. | Yes |
| 2019-07-30 | 0 | 0 | During routine operation a leak was detected on a 4||| boiler feedwater line. Upon investigation the piping was found to have been subjected to corrosion under insulation. | Yes |
| 2019-07-24 | 4 | 0 | During a planned outage, workers were removing the blind flange on a waste heat boiler when they were sprayed with hot boiler feedwater. | Yes |
| 2019-07-19 | 0 | 0 | During routine rounds, operators detected a leak in the economizer of a boiler. Investigation revealed a tube had failed, most likely due to fatigue. | Yes |
| 2019-07-17 | 0 | 0 | A compression fitting connection failed due to improper installation, resulting in a loss of process fluid. The fitting was not tightened to the manufacturer's specifications, resulting in insufficient crimping of the tubing. | Yes |
| 2019-07-16 | 0 | 0 | A pin hole leak was found on the condensate dump valve of an inlet separator. Sand erosion is believed to be the cause of the pin hole. | Yes |
| 2019-07-15 | 0 | 0 | The gasket on the inlet nozzle of a pressure vessel failed, allowing process gas to escape. The gas ignited after coming into contact with welding that was being performed in the vicinity. | Yes |
| 2019-07-09 | 0 | 0 | During operation the bellows on a PSV was found to be leaking. | Yes |
| 2019-07-09 | 0 | 0 | During plant start-up a blowdown header overpressured causing water hammer to occur. The water hammer caused a 3/4||| drain valve assembly to break. | Yes |
| 2019-07-09 | 0 | 0 | A crack was found in a connection weld on a coker. The crack is believed to have been caused by a high stress concentration at that location. | Yes |
| 2019-07-04 | 0 | 0 | A loss of containment was reported due to the failure of a 3/4 inch to 1/4 inch swage reducer in a transmitter line. The failure was located in the threaded area of the swage and was determined to be caused by vibration related fatigue. | Yes |
| 2019-07-02 | 1 | 0 | An operator was sprayed in the face with process fluid after turning a valve that was under pressure. | No |
| 2019-07-01 | 0 | 0 | A 2 inch elbow drain off an 8 inch truck load line failed due to external corrosion (elbow in soil). | Yes |
| 2019-07-01 | 0 | 0 | Oil was found leaking into the firetube of a fired treater. The treater was safely shut down, with no further consequences. | Yes |
| 2019-06-28 | 0 | 0 | An elbow in an acid piping system failed due to corrosion. Dew point corrosion is suspected, as Sulphur was known to be in the line causing corrosive acid to form. | Yes |
| 2019-06-24 | 0 | 0 | A gas leak caused Low Explosive Limit (LEL) detectors to shut down a booster compressor unit. The cause of the leak was found to be a through wall crack on the inlet of a safety valve. | Yes |
| 2019-06-24 | 0 | 0 | An operator discovered a leak below a discharge bottle in a compressor building. The leak was due to a cracked drain nipple on the discharge piping. | Yes |
| 2019-06-24 | 0 | 0 | Operators discovered a pinhole leak on an oil emulsion pressure piping line. Pinhole was found be caused by Corrosion Under Insulation (CUI). | Yes |
| 2019-06-21 | 0 | 0 | During startup of a process system, a pressure piping system failed in a dead-leg. | Yes |
| 2019-06-19 | 0 | 0 | Operators discovered a leak underneath a separator. The leak was due a pinhole in the bottom head of the vessel. | Yes |
| 2019-06-13 | 0 | 0 | During planned maintenance activities, materials inside a vessel were exposed to air, resulting in an exothermic reaction. | Yes |
| 2019-06-10 | 0 | 0 | A sandblast tank overpressured causing the manway cover to fail, launching it through a building roof. Upon investigation the safety relief valve was found to be wired shut. | Yes |
| 2019-06-04 | 0 | 0 | An employee failed to completely depressurize a sandblast tank before attempting to open the lid. The lid swung open, denting the vessel. | No |
| 2019-06-03 | 0 | 0 | A piping flange connection was found to be misaligned, allowing process gas to escape. The piping system was shut down without incident. | Yes |
| 2019-06-03 | 0 | 0 | A cracked 1 inch nipple was found leaking process fluid in a piping system, which was shut down without incident. | Yes |
| 2019-05-23 | 0 | 0 | Operators noticed low suction pressure on a compressor. Upon investigation several heat exchanger tubes were found to have failed due to corrosion. | Yes |
| 2019-05-21 | 0 | 0 | A high pressure steam boiler was found leaking water from three failed watertubes. The failure is believed to be due to corrosion of the tubes. | Yes |
| 2019-05-13 | 0 | 0 | Process fluid was found to be leaking from an elbow on a piping system. The elbow failed due to erosion. | Yes |
| 2019-05-06 | 0 | 0 | The firetube in a treater failed, allowing process fluid to escape. The fluid ignited, causing a fire which damaged the treater. | Yes |
| 2019-05-02 | 0 | 0 | A line heater was overfilled, which caused a loss of containment. The process fluid then ignited, causing a fire. | Yes |
| 2019-05-01 | 0 | 0 | An insulated process piping line was found to be leaking gas. Once the insulation was removed, the piping was found to be excessively corroded externally. | Yes |
| 2019-05-01 | 0 | 0 | A pinhole leak was found on the downcomer pipe between a reboiler and an accumulator. The equipment was shut down without incident. | Yes |
| 2019-04-25 | 0 | 0 | The gasket on an emulsion treater failed, allowing process fluid to escape. The facility was shut down and the gasket replaced. | Yes |
| 2019-04-17 | 0 | 0 | The weld on a steam header branch connection failed, allowing steam to escape. | Yes |
| 2019-04-17 | 0 | 0 | Process fluid was found to be leaking from a cracked nipple on a vortex scrubber. | Yes |
| 2019-04-17 | 0 | 0 | Several leaks were found throughout a process piping system. It was found that an unanticipated change to the corrosion inhibitor system resulted in an accelerated corrosion rate. | Yes |
| 2019-04-17 | 0 | 0 | The main gas valve on a high pressure steam valve failed open, allowing gas to accumulate. Upon start-up the accumulated gas ignited, causing an explosion. | No |
| 2019-04-16 | 0 | 0 | A power outage in a process plant caused the flow of thermal oil to stop. Power was restored, creating a water hammer condition which damaged the pressure vessel. | Yes |
| 2019-04-15 | 0 | 0 | A fire heater tube ruptured, causing a fire which damaged surrounding equipment. | Yes |
| 2019-04-15 | 0 | 0 | A waterwall tube in a high pressure hot water boiler developed a leak. Upon investigation, a casing attachment weld was found to have failed. | Yes |
| 2019-04-08 | 0 | 0 | During rounds, an operator noticed gas escaping from a nozzle weld on a third stage suction scrubber. The vessel was safely shut down and repaired. | Yes |
| 2019-04-08 | 0 | 0 | A cracked nipple was found on the bleed line from a compressor to flare. The line was shut down and the nipple repaired. | Yes |
| 2019-04-01 | 0 | 0 | The threaded inlet of a safety valve failed on a compressor skid, allowing gas to escape. | Yes |
| 2019-03-29 | 0 | 0 | Flammable material was inadvertently left in a pressure vessel used for heat treating products at a high temperature. The material ignited, causing a fire. | No |
| 2019-03-28 | 0 | 0 | A leak was discovered at the inlet nozzle of a pressure vessel. The leaking process fluid came into contact with hot piping and ignited, causing a fire. | Yes |
| 2019-03-26 | 0 | 0 | A pinhole leak was discovered in the union connecting the pressure gauge to the steam drum of a high pressure steam boiler. | Yes |
| 2019-03-22 | 0 | 0 | An atmospheric tank overfilled with glycol. The glycol came in contact with a nearby burner, igniting and causing a fire. | Yes |
| 2019-03-14 | 0 | 0 | A gasket leak in an ammonia refrigeration system in the mechanical room at an arena triggered an alarm which resulted in evacuation of the facility. | Yes |
| 2019-03-14 | 0 | 0 | An operator noticed steam coming from a line in a pipe rack. The plant was shut down and upon investigation the leak was determined to be caused by freeze damage to boiler feedwater line. | Yes |
| 2019-03-14 | 0 | 0 | In the process of restarting a primary separation facility that had been out of service for several months, the operator discovered a fuel gas scrubber leaking from freeze damage. | Yes |
| 2019-03-13 | 0 | 0 | Water was left in a shutdown process piping system and froze causing the pipe to split. When the process fluid was re-introduced a leak was discovered. | Yes |
| 2019-03-10 | 0 | 0 | An operator noticed steam leaking from a pipe and on investigation found a 2 inch long crack in the pipe. A passing block valve had allowed condensate to accumulate in an unheated portion of piping the condensate froze resulting in the pipe splitting. | Yes |
| 2019-03-09 | 0 | 0 | Failure of heat tracing resulted in two areas of splitting on a steam line due to freezing. | Yes |
| 2019-03-07 | 0 | 0 | Failure of heat tracing resulted in a drain line valve splitting due to freezing. | Yes |
| 2019-03-07 | 0 | 0 | Cast iron sectional steam heating boiler overheated due to a low water condition and failed. | Yes |
| 2019-03-04 | 0 | 0 | A power boiler safety valve was discharging as a result of an emergency shutdown of the boiler. The piping supports failed resulting in the vent piping being launched causing damage to nearby structures. Fortunately no injuries were sustained. | No |
| 2019-03-03 | 0 | 0 | A leak was detected in a top section of an economizer. The source of the leak was found to be at a tube weld. | Yes |
| 2019-03-01 | 0 | 0 | Steam line developed a leak as a result of corrosion causing a hazardous environment due to steam vapour cloud in the operating area limiting visibility. A engineered pressure enclosure was applied to eliminate the immediate hazard. | Yes |
| 2019-03-01 | 0 | 0 | A gasket leak was discovered at the channel to shell joint of a heat exchanger during startup following a maintenance outage. | Yes |
| 2019-03-01 | 0 | 0 | An operator noticed a small fire on a process gas header. Operations initiated a controlled shutdown without further incident. The source of fuel was process fluid that had leaked from cracked socket welds at drain connections. | Yes |
| 2019-02-28 | 0 | 0 | Abnormal flow induced vibration caused a crack to form in a weld-o-let fillet weld on a piping system. | Yes |
| 2019-02-25 | 0 | 0 | The bodies of two steam-jacketted process valves failed. The damage was cause by condensate that had accumulated in the valve bodies and froze due to failure of the associated steam traps. | Yes |
| 2019-02-24 | 0 | 0 | A leak was found on a steam sampling line. The line was supposed to be out of service, but the isolation valve was passing, allowing condensate to accumulate and freeze in the piping, causing it to rupture. | Yes |
| 2019-02-22 | 0 | 0 | A pipe nipple failed on a sight glass attached to sour gas suction scrubber leading to a release of gas which then ignited. The source of ignition was believed to be from hot engine components in the compressor skid package. | Yes |
| 2019-02-21 | 0 | 0 | Operators discovered a naptha leak in the inlet header piping at a branch connection to the main header. | Yes |
| 2019-02-21 | 0 | 0 | Operators found a naptha leak on the outlet header piping at a branch connection to the main header. | Yes |
| 2019-02-18 | 0 | 0 | Operators found a process line leaking gas. The source of the leak was found to be a crack in the heat affected zone of a reducer. | Yes |
| 2019-02-16 | 0 | 0 | Process fuel leaked from valves and ignited when it came into contact with hot piping below, causing a fire. | Yes |
| 2019-02-12 | 0 | 0 | Product froze in an air cooled heat exchanger tube due to low ambient temperature (-40C) and reduced flow. Freezing resulted in rupture of the tube which was revealed when the ambient temperature increased sufficent to melt the frozen product. | Yes |
| 2019-02-12 | 0 | 0 | A valve bonnet separated from the body releasing product. The failure was the result of freeze damage which occurred after maintenance work had been completed and the system was left without adequate insulation. | Yes |
| 2019-02-12 | 0 | 0 | Operators noticed process fluid dripping out of the insulation on a pressure piping system. Once the insulation was removed a pinhole leak was found in the piping at a weld. The system was shut down for repairs. | Yes |
| 2019-02-11 | 0 | 0 | A tube leak was discovered in a boiler economizer. The boiler was shut down repaired and leak tested. | Yes |
| 2019-02-11 | 0 | 0 | A loss of containment occurred in a process piping system due to a crack at the toe of a weld joining an 8” branch connection to a 14” pipe. | Yes |
| 2019-02-11 | 0 | 0 | Two air cooled heat exchangers sustained extensive freezing damage and were removed from service. | Yes |
| 2019-02-10 | 0 | 0 | Operators detected hydrocarbon leaking from an air cooled heat exchanger. The process was safely shutdown and the equipment isolated and purged for inspection. The leak was caused by freezing. | Yes |
| 2019-02-10 | 0 | 0 | A leak was discovered in a steam condensate line. The heat tracing system had failed resulting in freezing damage and loss of containment. | Yes |
| 2019-02-10 | 0 | 0 | A leak was discovered at a welded connection in a boiler economizer tube. | Yes |
| 2019-02-09 | 0 | 0 | Ammonia leaking from a fitting in the piping system resulted in evacuation of an ice area. | Yes |
| 2019-02-06 | 0 | 0 | Ammonia leak contained to mechanical room at an arena triggered an alarm and resulted in evacuation of the building. The source of the leak was an instrumentation connection near the compressor. | Yes |
| 2019-01-26 | 0 | 0 | Following startup of a compressor unit a small readily contained fire occurred due to leakage at a loose fitting. | Yes |
| 2019-01-24 | 0 | 0 | A leak occurred in a fitting in a process piping system due to impingment of steam injected into the process. | Yes |
| 2019-01-24 | 0 | 0 | Small bore piping on a compressor package developed a through wall crack. Inadequate support and vibrations is believed to be the cause of this failure. | Yes |
| 2019-01-22 | 0 | 0 | A deadleg in a steam condensate piping system failed due to freeze damage as a result of failure of the heat tracing system. | Yes |
| 2019-01-21 | 0 | 0 | An operator detected a hydrogen sulfide leak and shut the plant down. The source of the hydrogen sulfide was later determined to be a pinhole leak in a nozzle on a pressure vessel. | Yes |
| 2019-01-21 | 0 | 0 | A pressure piping system developed two through-wall leaks due to impingement of steam and process materials. | Yes |
| 2019-01-19 | 0 | 0 | Operations personnel detected process gas leakage from a piping system. The plant was safely shut down with no further consequences. | Yes |
| 2019-01-18 | 3 | 0 | A gas leak resulted in an explosion and fire in a compressor skid. | Yes |
| 2019-01-15 | 0 | 0 | A newly designed valve pass plate was installed into a valve and the flow pattern through the pass plate caused an erosive stream to the upper portion of the spool which led to the failure. | Yes |
| 2019-01-14 | 0 | 0 | A steam leak was discoverd on a steam header. Probable cause of tne leak is a fatigue crack at a support weld. | Yes |
| 2019-01-14 | 0 | 0 | Vertical air receiver sustained a crack at the weld to vessel interface, where the compressor base is welded to the head of the vessel. The unit was taken out of service. | Yes |
| 2019-01-14 | 0 | 0 | A tube in an air cooled heat exchanger failed due to freezing, causing the compressor to trip. | Yes |
| 2019-01-08 | 0 | 0 | A pinhole leak was discovered in a high pressure steam condensate line. | Yes |
| 2019-01-07 | 0 | 0 | A leak was discovered at a socket weld in a 1||| high pressure steam line. | Yes |
| 2019-01-04 | 0 | 0 | A remote site was left uninspected for several days in cold weather. Fuel gas to the unit heater was lost. The fuel gas scrubber (a fitting) was frozen and ruptured. | Yes |
| 2019-01-04 | 0 | 0 | During operation of a fired treater, the firetube failed due to localized overheating caused by scale fouling on the process side. | Yes |
| 2018-12-28 | 0 | 0 | A leak was found in a process piping system. Errosion-corrosion is the suspected damage mechanism. | Yes |
| 2018-12-17 | 0 | 0 | Gas leaked from a failed compressor cylinder valve cap O-ring resulting in a fire which damaged a pressure vessel. | Yes |
| 2018-12-16 | 0 | 0 | A leak was discovered in a section of process piping that had been isolated without freezing protection during a shut down. The leak was discovered when the frozen product thawed after start up. | Yes |
| 2018-12-16 | 0 | 0 | A steam leak was discovered at a flanged connection in a piping system soon after startup. The leak seems to have been the result of freezing damage that occurred during the outage. | Yes |
| 2018-12-13 | 0 | 0 | A heat exchanger tube bundle had been removed from the shell for maintenance. Process residue on the tubes ignited resulting in a small fire. | No |
| 2018-12-12 | 0 | 0 | A high pressure steam condensate line developed a leak and was shut down for repair. | Yes |
| 2018-12-10 | 0 | 0 | A gas leak from a sight glass gasket on a suction scrubber resulted in a fire in a compressor skid. | Yes |
| 2018-12-08 | 0 | 0 | The burner control on a process heater failed to shut down, resulting in overheating of the firetube. | Yes |
| 2018-12-07 | 0 | 0 | The expansion joint in the non-code firetube of a line heater failed resulting in loss of heat medium. | Yes |
| 2018-12-05 | 0 | 0 | A firetube flange gasket on a fired treater leaked, releasing process fluid. The leak was the result of over-torquing the flange bolts. | Yes |
| 2018-12-05 | 0 | 0 | Oil was found leaking into the firetube of a fired treater. The treater was immediately safely shut down, with no further consequences. | Yes |
| 2018-12-03 | 0 | 0 | Small bore piping on a compressor suction scrubber failed, releasing gas. The gas ignited causing an explosion and fire. | Yes |
| 2018-11-29 | 0 | 0 | Cold weather caused the contents (mud & water) of a well site separator to freeze, resulting in vessel rupture. The building unit heater was not in operation at the time. | Yes |
| 2018-11-29 | 0 | 0 | Operators discovered a tube leak in an air cooled heat exchanger. The leak was caused by freezing of liquids in the tubes. | Yes |
| 2018-11-29 | 0 | 0 | Low ambient temperature caused the water in the shell side of a lube oil cooler to freeze, resulting in shell rupture. | Yes |
| 2018-11-20 | 0 | 0 | An unexpected accumulation of water in a product transfer pipe froze and caused the pipe to split, releasing product. | Yes |
| 2018-11-20 | 0 | 0 | Operators discovered a process fluid leak in a piping system. Further inspection found two pinholes and significant wall loss due to corrosion in the area of concern. | Yes |
| 2018-11-15 | 0 | 0 | Operators discovered a leak at a flange on a PSV inlet. Further inspection revealed that the flange body had formed a pinhole leak. | Yes |
| 2018-11-13 | 0 | 0 | Plant operator found steam leaking from a steam heat coil. The source of the steam leak was found to be at a socket weld tee fitting. | Yes |
| 2018-11-07 | 0 | 0 | Service fluid leaked from an air cooled heat exchanger as a result of tube wall material loss. | Yes |
| 2018-11-01 | 0 | 0 | Operators found a process gas leak in a piping system. The source of the leak was determined to be a crack in the weld heat affected zone of a reducer. | Yes |
| 2018-10-30 | 0 | 0 | A bellows in a process unit failed due to stress corrosion cracking after a relatively short period of service. | Yes |
| 2018-10-30 | 0 | 0 | A process fluid leak was found under a heat exchanger. The source of the leak was found to be a nozzle that had deteriorated due to corrosion. | Yes |
| 2018-10-24 | 1 | 1 | A wellhead vessel failed. There was one fatality and one person injured. | Yes |
| 2018-10-23 | 0 | 0 | A socket weld cracked in a 2 inch pressure piping system releasing hydrocarbon which was detected by instrumentation and the plant was shut down without further incident. | Yes |
| 2018-10-23 | 0 | 0 | During start-up of a boiler, an unstable fire in the furnace led to a small fuel gas explosion, which resulted in damage to control wiring. | No |
| 2018-10-17 | 0 | 0 | Process leaked from a flanged connection resulting in a fire. The source of the ignition was hot work taking place in the vicinity. | Yes |
| 2018-10-17 | 0 | 0 | Instrument tubing failed resulting in uplanned shutdown of a power plant. | Yes |
| 2018-10-16 | 1 | 0 | During a process upset, a valve was opened to depressurize the system. Gas from the valve ignited in a flash fire, resulting in burns to the operator. | Yes |
| 2018-10-15 | 0 | 0 | A fuel gas supply hose failed in a compressor skid, resulting in a fire. | Yes |
| 2018-10-11 | 0 | 0 | Operators observed a leaking nipple on the discharge side of the compressor piping. The piping was safely isolated without further incident. | Yes |
| 2018-10-04 | 0 | 0 | Failure of a bi-metallic weld in a reformer furnace resulted in leakage of combustible hydrocarbon gas. There was no fire or explosion. | Yes |
| 2018-10-03 | 2 | 0 | A pressure vessel containing pyrophoric material was being prepared for inspection. When exposed to the atmosphere the pyrophoric material ignited causing a fire. | No |
| 2018-09-20 | 0 | 0 | A compression fitting failed in a pressure piping (tubing) system. | Yes |
| 2018-08-20 | 1 | 0 | A 500 gallon propane tank was being cut into pieces by hydraulic shears attached to a track hoe. When the pressure boundary of a tank was breached propane escaped forming a propane vapour cloud which ignited in a flash fire. | Yes |
| 2018-08-15 | 0 | 0 | A leak developed in a 2||| sulfuric acid transfer piping system. The leak resulted in approximately 500 kg of 98% sulfuric acid spilling to the ground. | Yes |
| 2018-08-14 | 0 | 0 | A firetube salt bath heater failed resulted in overheating and failure of the non-code shell. | No |
| 2018-08-10 | 0 | 0 | A piece of 1/2 inch stainless steel tubing connecting the autoclave to the condenser ruptured, releasing hot vapours and hydrogen gas above the auto ignition temperature of the mixture. A fire was the result. | Yes |
| 2018-07-24 | 0 | 0 | A process upset resulted in a lack of flow to a heat exchanger, causing localized overheating and a flange leak. Escaped process fluid ignited, causing a fire that was quickly extinguished by operations. | Yes |
| 2018-07-09 | 0 | 0 | A pumpjack engine back-fired and discharged embers onto combustible insulation which started to burn. Process instrumentation and control equipment was damaged by the fire. | No |
| 2018-07-09 | 0 | 0 | During operation of a fired treater the firetube failed (through-wall pitting), releasing process fluid. The fluid ignited causing a fire. | Yes |
| 2018-07-03 | 0 | 0 | A de-sanding valve in a SAGD facility failed releasing process fluids. | Yes |
| 2018-06-29 | 0 | 0 | Small bore piping (tubing) in high pressure liquid oxygen service failed. A small quantity of liquid oxygen was released prior to safe shut down of the plant. | Yes |
| 2018-06-28 | 0 | 0 | Steam header through wall crack leaking steam. Weld at repad developed crack along the toe of the weld. | Yes |
| 2018-06-27 | 0 | 0 | A leak was discovered between the tube sheet and tube of a glycol boiler. The unit was safely shut down. | Yes |
| 2018-06-22 | 0 | 0 | Company inspectors discovered propane tanks being used as air receivers and had them removed from service. | No |
| 2018-06-21 | 1 | 0 | An operator was hospitalized for treatment of burns caused by steam and hot water released from a steam-out hose connection. | No |
| 2018-06-19 | 1 | 0 | A worker was treated for burns caused by a flash fire which occurred while the worker was using a wash-wand to spray water into an open pressure vessel manway to prepare the vessel for internal inspection. | No |
| 2018-06-15 | 0 | 0 | Process piping was overheated from a high temperature reaction that occurred inside the pipe. | No |
| 2018-06-12 | 0 | 0 | Through wall corrosion of vent piping on a thermal liquid tank allowed thermal liquid to leak. | Yes |
| 2018-06-07 | 1 | 0 | The safety valves on a compressor package were removed for servicing. A process upset ocurred, introducing natural gas into the piping system which leaked from the openings, resulting in a fire. An operator was burned. | Yes |
| 2018-06-06 | 0 | 0 | Hydrocarbon leaked from the weld at a small bore piping branch connection resulting in a fire. | Yes |
| 2018-06-05 | 0 | 0 | Process piping was overheated from a high temperature reaction that occurred inside the pipe. | No |
| 2018-05-29 | 1 | 0 | During the shutdown of a boiler feedwater pump, a hose was used to drain the system. As the drain valve was opened and flow started, the hose whipped due to the discharge reaction and the operator was sprayed by hot water and burned. | Yes |
| 2018-05-29 | 0 | 0 | The shell of a heat exchanger in hot water service was deformed and developed a through-wall crack due to overpressure. | Yes |
| 2018-05-18 | 0 | 0 | Operators discoveed a leak at a nozzle weld on suction scrubber piping. The plant was shut in and depressurized with no consequential damage. | Yes |
| 2018-05-08 | 0 | 0 | During start-up of a power boiler, the steam drum manway gasket failed, releasing steam. | Yes |
| 2018-05-03 | 0 | 0 | Heating boiler furnace explosion resulted in damage to the boiler casing. | No |
| 2018-04-30 | 0 | 0 | Excessive heat input from an electric heater caused the shell of a pressure vessel to fail, releasing process fluid. The fluid ignited, causing a fire. | Yes |
| 2018-04-23 | 1 | 0 | A furnace explosion occurred during start-up of a power boiler. The operator was treated for burns in hospital. | No |
| 2018-04-20 | 0 | 0 | A heating boiler was destroyed by excessive heat from overfiring. | No |
| 2018-04-17 | 0 | 0 | Small bore piping on a compressor suction bottle failed, releasing gas which resulted in a fire. | Yes |
| 2018-04-15 | 0 | 0 | Small bore piping failure on engine fuel gas piping released fuel gas to building resulting in explosion and fire. | Yes |
| 2018-04-13 | 0 | 0 | Hydrocarbon leaked from a heat exchanger shell to channel joint resulting in a fire. | Yes |
| 2018-04-12 | 0 | 0 | Heating boiler furnace explosion resulted in damage to the boiler casing. | No |
| 2018-04-09 | 0 | 0 | Sight glass in a weak acid cation water softener failed, resulting in a loss of containment. | Yes |
| 2018-04-07 | 0 | 0 | An unintentional release of process fluid through a valve ignited, causing a fire. | Yes |
| 2018-03-26 | 0 | 0 | Fire destroyed 2 fuel gas scrubbers and associated piping. | No |
| 2018-03-19 | 0 | 0 | The contents in the depressurizing line from a pig receiver froze resulting in failure of the depressurizing line. | Yes |
| 2018-02-12 | 0 | 0 | During operation of a fired treater the firetube gasket failed, releasing process fluid. The fluid ignited causing a fire. | Yes |
| 2018-02-08 | 0 | 0 | During operation of a fired treater the firetube failed (through-wall crack), releasing process fluid. The fluid ignited causing a fire. | Yes |
| 2018-02-02 | 0 | 0 | The contents in a closed pressure vessel froze resulting in failure of the pressure vessel shell. | Yes |
| 2018-01-14 | 0 | 0 | The contents in a closed pressure vessel froze resulting in failure of the pressure vessel shell. | Yes |
| 2018-01-10 | 0 | 0 | A small bore piping (tubing) leak resulted in a fire in a compressor skid. | Yes |
| 2018-01-09 | 0 | 0 | A process upset resulted in a reaction fire inside a pressure piping system. | No |
| 2017-12-21 | 0 | 1 | Heating boiler exhaust piping failed causing flue gas to accumulate in a building. A worker died from exposure to carbon monoxide. | No |
| 2017-12-06 | 0 | 0 | Hydrocarbon released from flare stack ignited and destroyed fuel gas supply building. Hydrocarbon was from PSV discharging to flare stack. | Yes |
| 2017-11-30 | 0 | 1 | Pressure released from a sandblast hopper caused a worker to fall off the equipment. The worker later died of his injuries. | Yes |
| 2017-11-17 | 0 | 0 | An ammonia leak in an ice arena resulted in the evacuation of the building. There were no injuries reported. | Yes |
| 2017-11-16 | 0 | 0 | Hydrocarbon leaked from a valve packing gland in a process facility. The leak was detected, and activated the plant alarm. | Yes |
| 2017-11-01 | 0 | 0 | A hose used to transfer liquid hydrocarbon was overpressurized. | Yes |
| 2017-10-19 | 0 | 0 | Hydrocarbon leaked from a threaded plug in small bore piping vent. The leaked fluid caught fire. | No |
| 2017-09-22 | 0 | 0 | A tube leak resulted in a smelt water reaction in a recovery boiler furnace. | Yes |
| 2017-09-12 | 1 | 0 | Buried piping was damaged by construction activities, causing a hydrocarbon leak that resulted in an explosion. | Yes |
| 2017-08-28 | 0 | 0 | A gas leak in small bore braided hose resulted in a fire at a compressor station. | Yes |
| 2017-08-15 | 0 | 0 | Freeze damage was discovered during seasonal maintenance of out-of-service pressure piping. | Yes |
| 2017-08-02 | 0 | 0 | A flange gasket leaked process fluid from a treater vessel resulting in a fire. | Yes |
| 2017-07-13 | 0 | 0 | A hydrate plug formed in a piping system. The hydrate plug broke free and impacted a valve downstream, causing mechanical damage which resulted in a leak. | Yes |
| 2017-07-12 | 0 | 0 | Gas leaked from a flanged joint resulting in a fire. The fire was extinguished and there was no consequential damage. | Yes |
| 2017-07-11 | 0 | 0 | Lightning strike caused a fire at a separator building, damaging the pressure equipment inside. | No |
| 2017-06-20 | 0 | 0 | Through wall corrosion on the drain line of a fuel gas scrubber allowed process fluid to escape. Operators discovered the leak and initated an emergency shut down of the unit, preventing a fire from occuring. | Yes |
| 2017-06-16 | 0 | 0 | The threaded bonnet separated from the body of a pressure relief valve due to forces resulting from the discharge piping system freezing. | Yes |
| 2017-06-16 | 0 | 0 | During operation of a fired treater the firetube failed, releasing process fluid. The fluid ignited causing a fire | Yes |
| 2017-05-31 | 2 | 0 | A nonmetallic pipe failed during operation, releasing acid which contacted two operators. | Yes |
| 2017-05-22 | 0 | 0 | A procedural error in drawing process fluid from a system resulted in a small fire. | No |
| 2017-05-17 | 0 | 0 | The gasket failed in a treater firetube flange releasing oil which ignited resulting in fire damage to the treater, pop tank and building. | Yes |
| 2017-05-05 | 0 | 0 | During maintenance welding of structural steel, combustible material was ignited. The resulting fire damaged pressure vessels and piping. | Yes |
| 2017-04-04 | 0 | 0 | During operation of a fired treater, the firetube failed due to localized overheating caused by scale fouling on the process side. Process fluid leaked into the firetube, causing a fire. | Yes |
| 2017-03-31 | 0 | 0 | A leak at a weld released process fluid, which auto-ignited resulting in a small, localized fire, with no collateral damage. | Yes |
| 2017-03-14 | 1 | 0 | A process fluid leak in created a vapour cloud which ignited and caused a fire. One worker was treated for burns. | Yes |
| 2017-03-13 | 2 | 0 | During maintenance of an ammonia system a worker inadvertantly caused an isolation valve to partially open, releasing ammonia. Two workers were injured as a result of contact with the released ammonia. | Yes |
| 2017-02-19 | 0 | 0 | A through wall crack in a pressure vessel resulted in a loss of containment and fire. | Yes |
| 2017-02-12 | 0 | 0 | Firetube boiler furnace tube overheated and failed due to waterside fouling. | Yes |
| 2017-02-12 | 0 | 0 | During manual desanding of a separator vessel, the drain line became plugged and failed. | Yes |
| 2017-01-26 | 0 | 0 | During the hydrostatic pressure test of a pressure piping system, a valve failed in the test assembly used to connect the piping to the pressure source. | Yes |
| 2017-01-24 | 0 | 0 | A process heater overheated and failed during startup. | Yes |
| 2017-01-13 | 0 | 0 | A flash fire occurred in a compressor building. | No |
| 2017-01-12 | 0 | 0 | A gasket failed on a sour service oil treater. | Yes |
| 2017-01-04 | 0 | 0 | A fire occurred during the start-up of a compressor. | No |
| 2016-12-14 | 0 | 0 | Fluid leaked into off line compressor discharge piping and froze. Compressor cylinder was damaged by excessive pressure when compressor was started. | No |
| 2016-12-10 | 0 | 0 | Pin-hole leak in branch connection weld to pressure vessel nozzle released small amount of hyrdrocarbon resulting in a fire. The nozzle had corrosion resistant overlay, but the the branch connection did not. | Yes |
| 2016-11-24 | 0 | 0 | A control system malfunctioned releasing process fluids. The fluids ignited causing a fire. | No |
| 2016-11-15 | 0 | 0 | A fire in a compressor skid resulted in damage to pressure piping. | No |
| 2016-09-09 | 0 | 0 | A flange gasket in a pressure piping system containing heavy oil failed resulting in a fire. | Yes |
| 2016-09-08 | 0 | 0 | A furnace explosion occurred during start-up of a gas fired heating boiler. | No |
| 2016-08-12 | 0 | 0 | An engine fire damaged a fuel gas scrubber and the associated piping system. | No |
| 2016-06-22 | 0 | 0 | Process fouling in a heat exchanger resulted in localized overheating and loss of containment. | Yes |
| 2016-06-21 | 0 | 0 | Hydrocarbons were released due to operational error, resulting in a fire that caused no damage to the pressure equipment. | No |
| 2016-06-14 | 0 | 0 | Pressure vessels and piping were damaged by fire at natural gas wellsite. The fire is suspected to have been initiated by a lightning strike. | No |
| 2016-06-09 | 1 | 0 | An operator recieved first degree burns to hands and neck from blowback during light-off of fired treater burner. | No |
| 2016-05-18 | 0 | 0 | Liquid hydrocarbon leaked in a pumphouse, causing a fire that damaged pressure piping. | Yes |
| 2016-05-05 | 0 | 0 | A fibreglass pop tank caught fire at an unmanned wellhead facility. Pressure vessels and associated piping were damaged from heat exposure. | No |
| 2016-04-26 | 1 | 0 | An operator was draining a hot water storage tank. The threaded drain pipe swung due to reaction forces. The operator was burned by hot water and steam. | No |
| 2016-03-02 | 0 | 0 | Oil emulsion leaked into a fire tube in an idle free water knock out vessel. The oil was eventually ignited by the burner pilot resulting in a fire which damaged auxilliary equipment. | No |
| 2016-02-12 | 0 | 0 | During operation of a fired treater, a crack developed in the firetube releasing process fluid. The fluid ignited causing a fire. | Yes |
| 2016-02-11 | 0 | 0 | Accumulation of condensate in an isolated section of steam piping froze and caused the pipe to rupture. | Yes |
| 2016-02-10 | 0 | 0 | A hydrocarbon leak from a piping system in a processing facility resulted in a small fire. The plant was shut down safely with no further damage. | Yes |
| 2016-02-05 | 0 | 0 | During normal operation, process piping failed due to service induced deterioration. Corrosion under insulation was a factor. | Yes |
| 2016-02-04 | 0 | 0 | Unattended portable fired heater used to thaw frozen pressure equipment in a skid building ignited a tarp causing a fire. | No |
| 2016-01-22 | 0 | 0 | During normal operation a steam heating boiler overheated due to low water level. | Yes |
| 2016-01-18 | 0 | 0 | A through wall crack developed in process piping during operation. | Yes |
| 2016-01-15 | 0 | 2 | Explosion in hydrocracker unit. Two workers killed. | Yes |
| 2016-01-05 | 1 | 0 | Sight glass failure on a process vessel. Operator received burns to hands from hot liquid. | Yes |
| 2016-01-04 | 0 | 0 | A boiler blowdown line froze and ruptured due to inadequate heat tracing. | Yes |
| 2016-01-04 | 0 | 1 | A 20-pound propane bottle that had been filled with water and was being heated with a propane torch, to produce steam, when it failed catastrophically. One man was killed. | Yes |
| 2015-12-28 | 0 | 0 | A header in an air cooled steam condenser ruptured due to freezing. | Yes |
| 2015-12-28 | 0 | 0 | A compressor engine fire caused damage to a pressure vessel and associated piping. | No |
| 2015-12-15 | 1 | 0 | A fitting failed during start-up of a compressor following routine maintenance. A worker was struck and injured by debris. | Yes |
| 2015-12-09 | 0 | 0 | Fire caused by a flange leak during start-up of a heat exchanger in hydrocarbon service. | Yes |
| 2015-12-08 | 1 | 1 | A man-lift device struck a pipe in low pressure liquid ammonia service. The pipe broke releasing ammonia, resulting in one fatality. | Yes |
| 2015-12-07 | 0 | 0 | A through wall crack developed in process piping during operation. | Yes |
| 2015-12-03 | 3 | 0 | During maintenance a valve was removed from a propane tank, releasing propane gas. The propane gas ignited, causing an explosion. | No |
| 2015-12-01 | 0 | 0 | Fire caused by service-induced deterioration of a tube in a fired process heater during operation. | Yes |
| 2015-11-10 | 0 | 0 | A flange in high pressure steam service failed during start-up of the steam plant. | Yes |
| 2015-10-31 | 0 | 0 | Process piping failed due to freezing, as a result of inadequate heat tracing. Escaping hydrogen ignited causing a fire. | Yes |
| 2015-10-22 | 0 | 0 | Due to an improper air/gas ratio, a furnace explosion occurred in a boiler during operation. | No |
| 2015-10-21 | 1 | 0 | During maintenance of a heating plant, a safety valve unexpectedly relieved, releasing steam in the direction of a worker. | No |
| 2015-10-15 | 0 | 0 | During start-up, a process plant was overpressured due to an unexpected blockage in the piping. | No |
| 2015-10-08 | 0 | 0 | During maintenance on a refrigeration system in an ice rink, ammonia was inadvertantly released. | Yes |
| 2015-09-17 | 0 | 0 | Mechanical joint leak in a fired process heater. | Yes |
| 2015-09-14 | 0 | 0 | Unanticipated flow impingement caused abrasive wear to a pressure vessel, resulting in a pinhole failure. | Yes |
| 2015-09-04 | 0 | 0 | A mechanical joint failed releasing process fluid, which ignited and caused a fire. | Yes |
| 2015-08-30 | 0 | 0 | A threaded connection failed on compressor pressure piping. The failure released gas which ignited in the compressor building. | Yes |
| 2015-08-29 | 0 | 0 | During a planned shutdown, a heat exchanger gasket failed releasing process fluid. The fluid ignited, causing a fire. | Yes |
| 2015-08-29 | 0 | 0 | Due to external corrosion, a process piping line ruptured releasing process fluid. The fluid ignited, causing a fire. | Yes |
| 2015-07-29 | 0 | 0 | A pressure vessel overheated during a temperature excursion, resulting in permanent deformation of a section of the shell. | No |
| 2015-07-07 | 0 | 0 | During start-up of a new facility, a vessel was over-pressurized as a result of improperly operating controls and relief device. | No |
| 2015-06-25 | 0 | 0 | Due to an improper air/gas ratio, a furnace explosion occurred in a package boiler during start-up. | No |
| 2015-06-24 | 1 | 0 | An operator was burned by hot process fluids while preparing a vessel for inspection. | Yes |
| 2015-06-24 | 0 | 0 | A lightning strike caused a fire in an atmoshperic storage tank. The fire damaged nearby pressure equipment. | No |
| 2015-06-23 | 0 | 0 | During operation of a fired heater, a crack developed in the firetube releasing process fluid. The fluid ignited causing a fire. | Yes |
| 2015-06-16 | 0 | 0 | During operation of a fired treater, a crack developed in the firetube releasing process fluid. The fluid ignited causing a fire. | Yes |
| 2015-06-06 | 0 | 0 | A pressure vessel containing pyrophoric material was being prepared for inspection. When exposed to the atmosphere the pyrophoric material ignited causing a fire. | No |
| 2015-06-01 | 0 | 0 | During operation of a fired treater, a crack developed in the firetube releasing process fluid. The fluid ignited causing a fire. | Yes |
| 2015-05-20 | 0 | 0 | During maintenance of an ammonia refrigeration system, ammonia was inadvertantly released from the system. | Yes |
| 2015-05-12 | 0 | 0 | During upset conditions, a sulfur condenser tube was overheated and ruptured, releasing boiler feedwater. | Yes |
| 2015-05-08 | 0 | 0 | Due to operational upsets, a pressure vessel was damaged due to overheating. | No |
| 2015-05-02 | 1 | 0 | An operator was burned by process fluid while performing maintenance on a filter vessel. | Yes |
| 2015-04-13 | 0 | 0 | A heat exchanger leaked due to a crack on a welded seam. Natural gas was released, but there was no fire. | Yes |
| 2015-04-09 | 0 | 0 | Due to service induced deterioration, a heat exchanger tube failed at the tube-to-tubesheet connection, releasing process fluid. | Yes |
| 2015-03-20 | 0 | 0 | During start-up a pressure vessel was overpressured due to improper valve operation. | No |
| 2015-03-18 | 0 | 0 | During start-up of a power boiler, localized overheating resulted in the failure of several superheater tubes. | Yes |
| 2015-03-17 | 0 | 0 | An air hose connection separated on the discharge side of a compressor. The escaping air pressure and residual debris struck two workers. | Yes |
| 2015-01-28 | 0 | 0 | Due to an improper air/gas ratio, a furnace explosion occurred in a firetube boiler during start-up. | No |
| 2015-01-15 | 0 | 0 | A pressure vessel and associated piping were overpressured as a result of process fluid freezing in a blocked-in line. | No |
| 2015-01-12 | 0 | 0 | A safety relief valve failed at the inlet threads due to fatigue caused by vibration. | Yes |
| 2015-01-01 | 0 | 0 | During operation of a fired treater, the firetube ruptured releasing process fluid. The fluid ignited causing a fire. | Yes |