Non Sparking Tools Compliance Failures: Documented Fire & Explosion Events

Non sparking tools are a fundamental control for preventing ignition in environments where fuels and oxidisers are present. When these tools are not supplied or used, the risk of fire or explosion rises sharply.

The following documented incidents — drawn from OISD, PESO, OSHA accident reports, published investigations, regulatory summaries and credible news coverage — illustrate recurring failure modes involving spark-producing hand tools, powered cutters, and improper hot work on drums, pipes, and gas systems.

Purpose note: The case studies below are provided to increase awareness of ignition risks from spark-producing tools in flammable environments. Names of specific organisations are not highlighted; the intent is to learn from failures and improve safety practice.

Documented Fire & Explosion Events for non use of Non-Sparking Tools

1. Blast in Power Station

   A massive explosion at the generator–turbine of the 500-MW unit (Unit 7) of a power station occurred on 13 November 2019. An unattended hydrogen leak from the generator was identified prima facie as a major trigger. The unit was not shut down, and some workers who were unaware of the leak were trying to fix dirt blocks and loose nuts and bearings on the generator. Non use of spark proof spanners and equipment could have triggered sparks.

   
   

2. OSHA inspection #2272953 — Reactor kettle fire (methyl methacrylate)

   Two employees were tending a 100-gallon reactor kettle of methyl methacrylate in the mixing room. One employee used a metal wrench (vise-grips) to pry open the cover; the wrench handle struck an angle iron support and produced a spark. The spark was immediately followed by a massive fireball that engulfed both workers. Non-sparking tools were not provided. Several employees sustained first, second and third-degree burns.

   
   

3. Major fire at tank wagon siding

   While unloading a motor spirit (MS) tank wagon, contractors noticed an MS leak from a flange joint. Without closing the bottom and master valves, a worker tried to tighten the flange bolt with a spanner. The spanner slipped, fell and generated a spark that immediately ignited MS vapors. The MS tank wagon was engulfed by fire.

   
   

4. OSHA inspection #102826625 — Propane valve ignition

   An employee cleaning paint and replacing valves of propane cylinders opened a damaged valve to vent residual gas. An accumulation of gas and air formed around the work area and was ignited by a spark from the metal screwdriver used to open the valve. A fire and explosion followed, and the employee sustained second- and third-degree burns and was hospitalized.

   
   

5. Explosives factory — Pipeline cleaning using steel tools

   An investigative summary records an explosion in an explosives manufacturing unit where steel tools used to clean a process pipeline caused a fatal incident. The investigating agency explicitly cites use of sparking (Steel) tools as the causal factor.

   
   

6. OSHA inspection #124728437 — Manhole explosion (Allen wrench)

   Two maintenance mechanics working in a 30″ × 36″ manhole were changing a fuel pump. One mechanic used an Allen wrench to loosen bolts and created a spark that ignited gas fumes; an explosion occurred and the worker suffered burns to face, hands, arms and legs and was hospitalized.

   
   

7. Fire incident at a CCR Unit

   A major fire occurred at the Continuous Catalytic Reformer unit when valve(s) passing allowed hydrogen and naphtha to accumulate. Opening a drain flange released H₂ and naphtha, which caught fire either by auto-ignition or due to a spark generated while hammering the line without using non-sparking tools.

   
   

8. OSHA inspection #111109237 — Pipe cutting and tank explosion

   Workers cutting a metal pipe with a bandsaw and removing tank fittings generated sparks from the saw, pipe wrench or another source, igniting gas vapors. Three employees died from burns sustained in the explosion.

   
   

9. OSHA inspection #309178523 — Hydrogen tube trailer valve

   An employer was cited under the General Duty Clause for exposing employees to explosion hazard by opening a hydrogen tube trailer main valve without using non-sparking tools.

   
   

10. OSHA inspection #304994304 — LP gas tank maintenance with ferrous tools

    An employer was cited for exposing employees to fire/explosion hazards during maintenance on LP gas tanks using ferrous tools. OSHA specified implementing non-sparking tools as a feasible abatement method.

    
    

11. OSHA inspection #300983459 — LPG tanker valve installation flash fire

    Two employees installing an external valve assembly on an LPG tanker experienced a sudden release and ignition. The vapor ignited due to an ignition source that may have included sparks from ferrous hand tools or static; one employee later died from burn complications.

    
    

12. OSHA inspection #108916925 — Propane truck servicing fire

    While servicing a propane cylinder from a truck, a hose disconnection caused a gas discharge. The gas ignited — likely by a metal-to-metal spark or truck engine exhaust — and the employee was burned over 30% of his body.

    
    

13. OSHA inspection #305641094 — Propane cylinder filling

    An employer was cited under the General Duty Clause for exposing employees to fire/explosion hazards during cylinder filling operations, noting failure to use non-sparking tools to tap the filler valve to seat and close the valve’s check spring.

These incidents are avoidable. Non sparking tools are a low-cost and highly effective engineering control compared to the potential damage to property, infrastructure and—most importantly—loss of human life in case of an accident.

Facilities handling flammable liquids, solvents, gases, or combustible dust should regularly

review work permits, update standard operating procedures, and ensure the availability of certified non sparking tools.

For a comprehensive understanding of selection, applications, standards, and best practices, refer to our Ultimate Guide to Non-Sparking Tools for Industrial Safety.

If you are looking to improve safety in your plant, download our catalogue featuring 3,500+ certified non sparking tools or send us an RFQ. Our engineering team will help you select the right materials and sizes to meet your operational and compliance requirements.