Apr 26 2018, Husky Superior Refinery, Wisconsin exploded due to a failed spent catalyst slide valve between the reactor and regenerator. The explosion was so sever that the debris flew and hit and pierced through hot asphalt tank that was 200 ft away. Thus spilling hot asphalt and aggravating the danger.

Superior Refinery, the only refinery in Wisconsin is all set to start by the end of June 2023 after fighting to get through government clearance to rebuild and comply with 100s of regulations imposed by OSHA and reevaluating the process safety, rebuilding the control and safety system.

The key finding in 1000s of pages of documents from OSHA and several documents from CSB comes down under several categories as:

failure in design,
failure in operating procedures,
failure in maintenance,
failure in process safety management

In a retrospect, we the automation and safety engineers have highest responsibility in the more advancing and demanding social structure to ensure the safe and efficient operation. We the automation and safety leads have to stay extremely professional and followers of safety and regulations.

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