CSB Commends AFPM for Voluntary Refinery Safety Initiatives Following Husky Energy Investigation

What Happened

On March 23, 2026, the U.S. Chemical Safety and Hazard Investigation Board (CSB) issued a “Safety Spotlight” recognizing the American Fuel and Petrochemical Manufacturers (AFPM) for its leadership in chemical safety. The recognition follows AFPM's voluntary implementation of safety recommendations aimed at preventing incidents in fluid catalytic cracking (FCC) units.

Fluid catalytic cracking (FCC) units are among the most complex and hazardous process units in petroleum refining. They operate at temperatures exceeding 1,000°F and use finely powdered catalyst circulating between a reactor and regenerator at high velocities. The Husky Energy explosion occurred when an FCC unit's spent catalyst slide valve malfunctioned during a planned shutdown, allowing flammable hydrocarbons to contact air inside the regenerator vessel. The resulting deflagration sent debris across the facility and ignited secondary fires that burned for days.

The CSB investigation found that Husky's pre-shutdown safety review failed to account for known valve degradation, and that the facility lacked adequate blast-resistant buildings for personnel shelter. The board's final report, published in 2022, issued seven recommendations—including one to API to develop new industry guidance specifically for FCC unit shutdown safety. When API did not act on the recommendation, AFPM voluntarily stepped in.

The recommendations originated from the CSB's investigation into the 2018 explosion and fire at the Husky Energy refinery in Superior, Wisconsin. That incident resulted in 36 worker injuries and more than $550 million in property damage. The explosion occurred during a refinery shutdown when a flammable mixture of air and hydrocarbons ignited after safeguards failed.

Why It Matters

FCC-related incidents have historically accounted for some of the refining sector's most catastrophic losses. The 2015 ExxonMobil Torrance refinery explosion—another FCC unit failure—launched an 80,000-pound catalyst hopper that narrowly missed a modified hydrofluoric acid (MHF) storage tank. Had it struck, the release of MHF could have created a toxic vapor cloud threatening surrounding communities. These incidents underscore why FCC safety guidance carries weight beyond facility property lines.

Under OSHA's Process Safety Management (PSM) standard (29 CFR 1910.119), refineries operating FCC units must maintain comprehensive process hazard analyses, mechanical integrity programs, and management of change procedures. AFPM's new checklists and guidance documents provide a practical framework for facilities to benchmark their PSM programs against the specific failure modes identified in the Husky and Torrance investigations.

Refinery safety protocols are critical for industrial operators and EHS leads who manage high-hazard processes. The CSB had originally directed its recommendation for new FCC safety guidance to the American Petroleum Institute (API). However, AFPM took independent action to launch a comprehensive safety initiative for the sector.

The CSB reported that AFPM's actions fulfilled the agency's safety objectives even though the organization was not the intended recipient of the recommendation. This voluntary compliance suggests a shift in industry leadership, where trade organizations implement safety improvements even when not the primary target of regulatory or investigative directives.

Key Details

AFPM’s initiative reached a significant portion of the North American refining sector through direct outreach and digital resources. The program included the following components:

• 18 in-person safety workshops conducted for industry professionals.
• Participation from over 700 individuals representing 76 refineries across the United States and Canada.
• Development of a publicly accessible FCC Process Safety webpage.

The resources provided by AFPM include checklists, bulletins, and technical guidance. These materials specifically incorporate lessons learned from both the 2018 Husky Energy incident and a previous incident at the ExxonMobil Torrance refinery. CSB Chairperson Steve Owens said, “AFPM voluntarily stepped up and delivered real tools to help prevent future FCC-related incidents.”

What To Watch Next

The CSB’s recognition of AFPM aligns the group with other organizations like the International Association of Drilling Contractors (IADC) and the Center for Offshore Safety (COS) that have voluntarily implemented agency recommendations. Operators should monitor the CSB’s “Safety Spotlight” series for further industry-specific guidance.

As the CSB continues to close out recommendations from major investigations, industrial facilities using FCC units may see these voluntary standards become the de facto baseline for safety inspections and internal audits. Refining and petrochemical firms should review the new AFPM checklists and bulletins to ensure their shutdown procedures align with these updated industry lessons.