How did welding repairs and insulation changes increase risk?

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Welding Repairs and Insulation Modifications Contributed to Deadly Tuas Factory Explosion

A Singaporean company, Stars Engrg, has been fined S$500,000 and its director, Chua Xing Da, sentenced to 18 months and one week in jail following a fatal 2021 explosion at its Tuas industrial plant. The incident, which killed three workers and injured seven, occurred due to unsafe operation of a heated mixing machine, a situation exacerbated by the company's decision to perform welding repairs and modify the machine's heat insulation system without consulting the manufacturer. Investigations revealed that Chua personally oversaw the machine's installation and operation, often relying on his own assumptions rather than seeking expert advice, despite the machine exhibiting warning signs such as overheating and oil leaks over an extended period.
Welding and Insulation Modifications Undermined Machine Safety

The company, Stars Engrg, failed to consult the manufacturer before undertaking welding repairs and altering the heat insulation system of the mixing machine. This lack of consultation meant that modifications were made without a full understanding of the equipment's operational parameters and safety requirements. Such alterations could have compromised the machine's integrity, potentially increasing its susceptibility to overheating or creating new ignition sources, especially when combined with other operational deficiencies.
Unsafe Operation and Maintenance Led to Catastrophe

The mixing machine was operated unsafely over a prolonged period, despite numerous warning signs including overheating, oil leaks, and a prior fire incident. District Judge Tan Jen Tse highlighted that Chua, the director, made critical decisions regarding the machine's operation, such as determining the heating oil quantity and running it as a closed system, without adequate technical knowledge. The prosecution argued that these actions, coupled with unauthorised modifications, directly led to the safety failures that culminated in the explosion.
Combustible Powders Contributed to Secondary Fires

Beyond the initial explosion caused by the mixing machine, the incident was also worsened by inadequate controls over combustible powders present at the plant. These powders, when exposed to the initial blast or heat, likely contributed to secondary flash fires. The inquiry committee concluded that these failures in managing combustible materials were a significant factor in the overall catastrophe, compounding the initial safety breaches related to the machinery itself.

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How did welding repairs and insulation changes increase risk?

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