Deadly Gas Leak at Pemex Deer Park Refinery Linked to Identification Failures

A fatal hydrogen sulfide release at Pemex’s Deer Park refinery in Texas was caused by the absence of a standardized system to identify idled equipment, according to a report issued Monday by the U.S. Chemical Safety and Hazard Investigation Board (CSB). The incident occurred on October 10, 2024, when workers preparing an idled, de-inventoried unit mistakenly opened a flange on a nearby pipe connected to an operating unit, triggering the release of toxic gas.

Approximately 27,000 pounds of hydrogen sulfide — a highly poisonous gas — escaped into the air. One worker who opened the flange died at the scene, while a second worker downwind was overcome by the fumes and also died after being unable to escape. Gas concentrations reached at least 500 parts per million, and 13 additional workers required medical evaluation. Authorities in nearby Pasadena and Deer Park issued shelter-in-place orders as the gas cloud spread through surrounding communities.

The CSB report found that although the refinery had standardized procedures for pipe cutting, it lacked clear protocols for flange opening and blind removal activities. Investigators concluded that standardized markings for all line-opening work could have prevented the tragedy. Following the incident, the refinery has implemented a new system to properly identify equipment scheduled for maintenance, though a Pemex spokesperson did not immediately comment on the findings.

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