What warning signs like overheating and oil leaks were ignored before the 2021 blast?

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Warning Signs of Overheating and Oil Leaks Preceded Fatal 2021 Tuas Blast

Before the fatal explosion at the Tuas industrial plant in 2021, warning signs such as overheating and oil leaks from the mixing machine were ignored. The machine had been operated unsafely over an extended period, despite these and other indicators of potential danger. A fire also occurred shortly before the blast that ultimately killed three workers and seriously injured seven others.
Repeated Technical Problems Overlooked

The director, Chua Xing Da, personally oversaw the installation and operation of the mixing machine, training workers and approving repairs. Despite repeated technical problems, he made operational decisions based on his own assumptions rather than consulting the Chinese manufacturer. The manufacturer had offered technical assistance, but Chua attempted to troubleshoot the equipment himself, indicating an incomplete understanding of its functioning.
Inadequate Maintenance and Modifications

The company also failed to seek the manufacturer’s advice before carrying out welding repairs and modifying the machine’s heat insulation system. Investigations revealed that the machine had been operated unsafely for a considerable time, with overheating and oil leaks being among the persistent warning signs. The prosecution argued that Chua made critical decisions, such as determining heating oil amounts and operating the mixer as a closed system, which contributed to the safety failures.
Contributing Factors Identified Post-Incident

An inquiry committee concluded that the explosion could have been prevented. The incident was attributed to serious failures in the operation and maintenance of the mixing machine. Furthermore, inadequate controls over combustible powders contributed to secondary flash fires, exacerbating the initial event. These findings led to enhanced workplace safety requirements for high-risk machinery and combustible dust, which took effect in January 2025.

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What warning signs like overheating and oil leaks were ignored before the 2021 blast?

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