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The CSB’s investigation identified deficiencies in the company’s hot work policies and procedures as well as the contractors hired to execute the work. The CSB’s final report highlights key safety lessons learned from the incident at the Sunoco facility, which can prevent future hot work incidents. On 12 August 2016, hot work was being conducted by L-Con, a contractor of Sunoco, on a section of pipe that contained residual crude oil. The pipe segment was plugged on both ends by CARBER, a contractor hired by L-CON using an isolation device. During the welding operation on the inside surface of a flange, vapor inside the pipe gathered between two of the installed isolation tools and ignited. The ignition caused a build-up in pressure which led to a violent explosion at either end of the isolated pipe. Both Sunoco and L-Con developed plans and procedures to provide employees with guidance on how to safely conduct hot work operations, but the CSB found that guidance was inadequate to prevent the fire and explosion. Specifically, the investigation found that the pipe involved in the incident contained residual flammable crude oil which was not adequately cleaned or inerted prior to commencing hot work. The CSB concluded that Sunoco’s hot work procedure did not adequately state that hot work on equipment that currently or previously contained flammable material, was not permitted by OSHA or NFPA 51B. Additionally, the procedure did not clearly explain how to ensure that equipment was to be cleaned or inerted to safely conduct hot work. Therefore, Sunoco, and subsequently L-Con, did not implement adequate mitigation strategies to prevent a fire or explosion during hot work activities.

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