Forensic Engineering Evaluation of Utility Compressor Truck Explosion/Fire

Abstract

A compressed air system installed as a package on a utility company truck experienced a pressure boundary rupture in service, resulting in burning lubricant discharge onto an employee. Numerous design and component defects were alleged, and a series of expert group examinations of the truck, compressor system, and components occurred over the course of approximately three years. The author was retained by one of more than 20 component suppliers involved in this evaluation. Key issues included design of the compressor system and individual components in the pressure boundary, control system, and cooling system. Based on inspection and analysis, there were several causes for this incident that involved individual component and system design deficiencies, installation deficiencies, and operator training inadequacies.