Cause Determined in Ohio Refinery Fire That Killed 2

The U.S. Chemical Safety and Hazard Investigation Board (CSB) issued its final investigation report into the fatal naphtha release and fire at the BP-Husky Toledo Refinery (“BP Toledo Refinery”) in Oregon, Ohio, on September 20, 2022, which resulted in the death of two BP employees, who were brothers.

During an emergency situation at the refinery, liquid naphtha was released from a pressurized vessel, which resulted in a vapor cloud that subsequently ignited, causing a flash fire, which fatally injured the two BP employees. The events on September 20, 2022 resulted in approximately $597 million in property damage at the refinery, including loss of use. Over 23,000 pounds of naphtha were released during the incident.

This is the largest fatal incident at a BP-operated petroleum refinery in the United States since the fatal explosions and fires at the BP refinery in Texas City, Texas, in 2005, that resulted in the deaths of 15 workers and injured 180 other people.

The CSB’s report details a series of cascading — and worsening — events throughout the day of September 20, 2022, that contributed to the release and fire. The CSB found that there was an “alarm flood”, with more than 3,700 alarms going off in the 12-hour period prior to the fatal incident, which overwhelmed and distracted BP’s board operators, causing delays and errors in responding to critical alarms.

The CSB also found that the refinery failed to implement a shutdown or hot circulation through the use of stop work authority or otherwise in time to prevent the fatal incident.

As a result of its findings, the CSB is issuing a total of seven safety recommendations to the current owner of the facility (Ohio Refining Company LLC, a subsidiary of Cenovus Energy Inc., which acquired the refinery from BP in February 2023); the American Petroleum Institute (API); and the International Society of Automation (ISA). Each recommendation aims to address an existing safety gap.

The CSB did not make any recommendations to BP, since BP no longer operates the Toledo Refinery.
The CSB’s board members are appointed by the President subject to Senate confirmation. The Board does not issue citations or fines but makes safety recommendations to companies, industry organizations, labor groups, and regulatory agencies such as OSHA and EPA.

Source: CSB

Topics Ohio