HSE-RM SOLUTIONS | Technical review | 4 November 2026
The fire reported at Supreme Petrochem in Panoli raises a practical question for used-oil processing facilities: what sequence could bring a combustible release, air and an ignition source together, and which controls should interrupt that sequence?
Investigators need to establish the material involved, the operating stage, the first release or abnormal condition, the ignition source and the reasons the event escalated. The scenarios below are an investigation framework for this type of processing industry, not findings about Supreme Petrochem.
The incident and the industry
Sandesh reports a fire and blasts at Supreme Petrochem, Panoli GIDC, with three workers seriously burnt. It reports attendance by the Directorate of Industrial Safety and Health, Gujarat Pollution Control Board and police, while stating that an official cause had not been established. An agency attending the scene is not equivalent to an agency issuing a cause determination.
A historical GPCB list of actual users, dated 31 March 2024 and available through a third-party document archive, identifies Supreme Petrochem, GPCB ID 78567, Plot C1-B 1708, GIDC Panoli, against used oil. The June 2023 list records a capacity of 2,160 tonnes per year. This supports a used-oil processing or recycling connection. These records do not establish the present equipment, exact process, current authorisation status or equipment involved in the fire.
Comparable operations in Gujarat
The following examples identify the broader sector. Historical listing
does not establish that a facility remains operational or uses the same process
as Supreme Petrochem.
|
Facility |
Gujarat location |
Evidence of comparable activity |
|
ABC Organics & Chemicals |
Panoli, Bharuch |
Used oil in the March 2024 GPCB list |
|
Royal Petro Oil Refinery LLP |
Gandhidham, Kutch |
Used oil in the same list |
|
Classic Oil Refinery |
Choryasi, Surat |
Used oil in the same list |
|
Greenspace Enviro Services |
Anand district |
Its own website describes used/waste-oil
re-refining using thin-film evaporation, producing base oil and light oil |
Sources: GPCB List (https://legalupdate.qhsealert.com/file/202_Actual%20users%20for%20Used%20Oil%20%26%20Waste%20Oil.pdf)
These are examples of related operations, not allegations of unsafe
conditions. A sector review should group facilities by their actual feedstock,
heating method, distillation technology, inventories and safeguards.
How the process can create fire hazards
A representative re-refining route includes receipt and storage, solids
removal, dehydration, removal of lighter fuel fractions, distillation,
condensation, product collection and finishing. Vacuum or wiped-film equipment
is used in some processes. Other recovery plants have different arrangements. (Source:
https://chemsept.in/Views/Projects/UsedOilRefining.aspx)
Used oil is a variable feedstock. Water, particles and chemicals can
enter it during service or collection. Its hazards cannot be assessed solely
from the original lubricant specification.
Vapour generation is expected during distillation. An
explanation such as “gas formed” must establish whether this was normal
evaporation, unexpected volatile contamination, steam generation or
decomposition. It must then explain the release, pressure conditions and
ignition.
Fuel and oxidiser identification
|
Material or condition |
Where to look |
Why it matters |
|
Used oil with lighter fuel or solvent
contamination |
Incoming tankers, drums, feed tanks and mixed
batches |
Volatility and ignition behaviour may differ from
the expected feed |
|
Light hydrocarbon fractions |
Defueling equipment, condensers and receivers |
A release can create an ignitable vapour mixture |
|
Heated oil and oil mist |
Pumps, flanges, hoses, seals and pressurised lines |
Leakage can supply a pool fire or dispersed
combustible spray |
|
Heating-system fuel or thermal fluid |
Burner fuel trains and hot-oil circuits, where
installed |
The heating utility can supply the first fuel
release |
|
Oily residues and contaminated materials |
Still bottoms, sludge, insulation, filters and
rags |
They can contribute to fire growth; some deposits
require assessment for self-heating |
|
Air entering process equipment |
Vacuum leaks, open connections and maintenance
openings |
Oxygen can enable combustion where combustible
vapour is present |
Oil-mist hazards need separate consideration from bulk-liquid flash
point. Air is the oxidiser in these scenarios, not the fuel.
Hazard identification across the facility
This screening register must be developed against the site's equipment and operating limits. It is neither exhaustive nor a probability ranking.
|
Area and deviation |
Credible mechanism to examine |
Controls to assess |
|
Feed receipt and mixing |
Unexpected volatile or incompatible contamination
changes the batch hazard |
Traceable receipts, defined acceptance criteria,
representative testing and segregation of uncertain material |
|
Wet feed entering a hot process |
Rapid vaporisation causes foaming, carryover,
ejection or pressure rise |
Water assessment, controlled dehydration and
charging, appropriate operating limits and pressure protection |
|
Excess heat or low inventory |
Local overheating, exposed heated surfaces or
degradation of susceptible material |
Temperature and level protection; circulation
monitoring where applicable; limits based on feed and residue properties |
|
Vacuum failure or air ingress |
Operating conditions change; an ignitable mixture
may develop |
Leak integrity, pressure monitoring, defined
shutdown response and engineered inerting where justified |
|
Condenser or cooling failure |
Vapour is not adequately condensed and reaches
unintended locations |
Cooling performance monitoring, suitable trips and
safe handling of uncondensed vapour |
|
Restricted vapour or relief path |
Pressure rises because generation exceeds
discharge capacity |
Verified relief basis, blockage inspection,
controlled valve positions and safe discharge arrangements |
|
Receiver overfill or open collection |
Liquid or vapour escapes near people or ignition
sources |
Closed collection, suitable level protection,
controlled transfer and ventilation |
|
Pump, flange or hose leakage |
Hot oil or light fractions contact an ignition
source |
Mechanical integrity, compatible components, leak
detection and accessible emergency isolation |
|
Heater or thermal-fluid fault |
Fuel or hot fluid leaks; abnormal combustion or
overheating occurs |
Appropriate burner safeguards, fuel isolation and
circulation/temperature protection |
|
Maintenance during operation |
Hot work, opening equipment or temporary wiring
introduces ignition or releases material |
Isolation, permits, atmosphere testing, contractor
supervision and coordination of simultaneous work |
|
Storage and drainage |
A local release spreads through drains or exposes
adjacent inventories |
Compatible segregation, containment, drain
control, access and emergency planning |
|
Startup, shutdown or modification |
Valve alignment, utilities or controls differ from
normal operating assumptions |
Specific procedures, change review, readiness
checks and competent shift handover |
The register combines process, equipment and activity scenarios.
Heating or vacuum loss does not automatically cause decomposition; that depends
on the material and conditions. A pressure event also does not automatically
establish a combustion explosion.
Ignition sources and the precautions they require
Electrical equipment and portable devices
Assess motors, switches, junction boxes, instruments, temporary cables,
lamps and portable equipment against the hazardous-area classification.
Equipment suitability includes its protection method, gas group, temperature
class and installation condition. “Flameproof motor installed” is not a
complete assessment.
Flames and hot surfaces
Check fired heaters, burner fronts, exhausts, exposed hot pipework and
vehicle routes against credible vapour releases. A leak reaching a heater can
ignite without an electrical fault. Verify separation and the conditions under
which heating must stop. (Use Guide: https://www.hse.gov.uk/comah/sragtech/techmeasareaclas.htm)
Static discharge
Review tanker unloading, pumping, filtration, filling and sampling.
Verify bonding continuity and earthing of conductive equipment, suitable hoses
and transfer methods. Earthing metal equipment alone does not resolve charging
of an insulating liquid, hose or container. Avoid prescribing one flow limit
for every material and arrangement. (Earthing Guide: https://www.hse.gov.uk/comah/sragtech/techmeasearthing.htm)
Welding and other maintenance
Consider alternatives to hot work. Where it is necessary, isolate
relevant equipment, assess connected and adjacent vessels, and use suitable gas
testing before and during work. The permit must describe actual precautions and
supervision. An empty-looking oil vessel may still contain hazardous residue or
vapour.
Mechanical heat and contaminated insulation
Inspect bearings, alignment and abnormal vibration. Investigate
oil-soaked insulation and persistent leaks, particularly around hot equipment.
Replacing insulation without finding the leak can leave the underlying hazard
in place.
Controls that function when demanded
Establish the required response to excessive temperature, low
inventory, loss of circulation, cooling failure and abnormal pressure. Verify
the complete protective function, including sensors, logic, final isolation
devices and essential utilities. Independence, bypass management and proof
testing matter. A shutdown must reach a defined safe state; some processes
require cooling to continue after heating stops.
Evidence authorities should examine
Life safety and scene stabilization take priority. Once access is safe,
preserve evidence before dismantling, cleaning or restarting equipment. Record
emergency actions that changed valve positions, power supplies or equipment
condition.
|
Investigation question |
Evidence to seek |
|
Where did the event begin? |
CCTV, first witness observations, fire-service
records, original equipment locations and competent fire-origin examination |
|
What material was being processed? |
Batch identity, receipts, supplier history,
retained feed and product samples, laboratory results and tank-transfer
records |
|
What was the operating stage? |
Charging, heating, dehydration, distillation,
discharge, cleaning or startup records |
|
What changed before the event? |
Time-aligned temperature, level, pressure/vacuum,
cooling, flow, power and alarm histories |
|
Where did material first escape? |
Seal and flange condition, pipe failures, vessel
openings, receivers, drains, vent outlets and vacuum-pump discharge |
|
What supplied ignition? |
Heater operation, electrical examination, hot-work
records, static-control evidence, hot surfaces and vehicle activity |
|
Did pressure failure precede fire? |
Vessel deformation, fracture assessment, relief
condition, pressure history and the sequence visible in recordings |
|
Why did protection not stop escalation? |
Setpoints, response times, calibration, complete
trip tests, bypass records, isolation performance and shared utility failures |
|
Why were workers exposed? |
Work positions, access routes, warning, emergency
shutdown access, supervision and evacuation arrangements |
|
What changed recently? |
Feed suppliers, throughput, temperatures, piping,
equipment, staffing, maintenance and operating procedures |
Testing should be planned by competent investigators, with samples and
components documented and preserved. The table is a proposed evidence plan, not
a statement that these records exist at the site.
A burnt cable alone cannot establish that an electrical fault started
the fire. A damaged vessel alone cannot establish that an explosion initiated
it. Both may be consequences of an earlier event. Competing explanations should
be tested against the sequence and physical evidence.
HSE's investigation framework distinguishes immediate events from the
underlying arrangements that allowed them. The review should therefore also
examine competence, maintenance, communication and how identified defects were
managed.
Suggested coordination between authorities
Within their respective powers, a coordinated review could allocate
these workstreams:
- Fire service and
forensic specialists: origin, first fuel, ignition sequence, spread
and emergency-response observations.
- DISH: process
design, operating limits, machinery integrity, protective functions, work
practices and management arrangements.
- GPCB: actual
feed and waste streams, approved activities and consent conditions,
storage, residues, emissions and contaminated runoff.
- Police and
forensic laboratory: witness evidence, preservation and examination of
relevant components and samples.
- District and
industrial-estate emergency teams: mutual aid, access, adjacent
exposures, off-site consequences and communication.
These are suggested technical workstreams, not a substitute for each
agency's statutory remit. Current approvals should be checked directly; an old
list cannot establish whether a renewal was granted.
Actions for similar facilities
Operators can review credible hazards without assuming that the same
failure occurred at Panoli. Start with feed acceptance, heating limits,
condenser performance, vapour discharge routes, leak history, ignition controls
and functional testing of shutdowns.
Where a critical safeguard cannot be demonstrated or a dangerous
condition exists, have competent personnel assess whether the affected
operation can continue safely. Set corrective actions and restart conditions
around the actual hazard.
Fire protection, containment and emergency response remain necessary
because preventive controls can fail. Their adequacy should reflect the
inventories, release scenarios and neighbouring exposures.
An authority's sector advisory would be most useful if it identifies
the failed mechanism, the equipment and operations to which it applies, the
checks required, the acceptance criteria and responsibility for closure.
Confirmed findings should be distinguished from unresolved hypotheses.
HSE-RM SOLUTIONS perspective
The useful outcome of an investigation is an explanation that leads
to verifiable risk reduction.
For used-oil processing, that means connecting feed characteristics,
process conditions, equipment integrity, operating activities and human
decisions. It means establishing which safeguards were needed, whether they
worked and how their effectiveness will be maintained.
HSE-RM SOLUTIONS can support this approach through process hazard
identification, focused HAZOP studies, ignition-source reviews, equipment and
protective-system assessments, and practical operating and emergency
procedures.
Identify the hazardous sequence. Interrupt it. Verify the control.
HSE-RM
SOLUTIONS
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