Investigation Report
Shell Polymers Furnace Explosion and Fire — Furnace Explosion and Fire at Shell Polymers
Shell Polymers Furnace Explosion and Fire — Furnace Explosion and Fire at Shell Polymers
- CSB
- Investigation Report
- ExplosionFireFunctional safetyHuman factorsProcess safety
- Inspection and maintenance
- Operator displays and control interfacesProcess pipework and pipelinesValve
- Alarm managementHuman-centred designEnergy and process isolationOperating and work procedures
- Downstream and process industries
- Onshore facility
Summary
Investigates the June 2025 furnace explosion and fire at Shell Polymers Monaca following coke-trap cleaning. Inadvertent opening of isolation valves allowed cracked gas to enter the firebox and ignite. The report examines reliance on administrative safeguards, safety instrumented system bypasses, alarm suppression and confusing valve interfaces, recommending engineered protection and improved interface design.
Classifications: Explosion; explosive atmospheres.
Classifications: Fire; fire safety.
Classifications: Functional safety; safety instrumented systems; SIS.
Classifications: Human factors; human performance; ergonomics.
Classifications: Process safety; major accident hazards.
Classifications: Inspection and maintenance; asset inspection; equipment maintenance.
Classifications: Operator displays and control interfaces.
Classifications: Process pipework and pipelines; process piping.
Classifications: Valve; valves.
Classifications: Alarm management.
Classifications: Human-centred design.
Classifications: Energy and process isolation; isolation; energy isolation.
Classifications: Operating and work procedures.
Classifications: Downstream and process industries; refining; petrochemicals.
Classifications: Onshore facility; onshore plant.