Undefeated Refinery Accident Lawyer
What happens when a routine shift at a Shell refinery or chemical plant suddenly turns catastrophic? Within mere moments, a flash fire, explosion, or chemical release can completely upend the lives of injured workers and their families — leaving them to face a future that’s anything but certain. For most, the initial shock is only the beginning. The bills keep coming, and when workers’ comp finally kicks in, wage-replacement benefits don’t come close to covering their missed paychecks or even their basic living expenses.
Our Undefeated Refinery Accident Lawyers have successfully represented thousands of injured workers in Texas, Louisiana and throughout the United States. We understand the challenges confronting our clients, and we know just how far a powerful corporation like Shell will go to avoid paying victims of its negligence the compensation they deserve, even when the company is clearly to blame. That’s why we fight so hard to hold these companies accountable and ensure our clients have access to the financial resources needed to care for themselves and their families for the rest of their lives.
What to Know About Shell USA
Houston, Texas-based Shell USA operates nine industrial facilities across the country, including refineries and chemical plants in Texas, Louisiana, California, and Pennsylvania. Thousands of men and women—both Shell employees and contractors—support these operations, working daily in an environment where there’s little margin for error.
Shell Deer Park — Deer Park, Texas
Located along the Houston Ship Channel, Shell’s Deer Park site is one of its most important U.S. manufacturing centers. The facility includes both a refinery and a chemical plant, producing gasoline, diesel, jet fuel, aromatics, solvents, and a wide range of base chemicals used in plastics and industrial applications. Deer Park workers operate distillation towers, reformers, cracking furnaces, hydrotreaters, boilers, compressors, pipelines, and marine loading systems.
Shell Geismar — Geismar, Louisiana
Shell’s Geismar Chemical Plant is one of the country’s largest producers of ethylene oxide, ethylene glycol, and related intermediates. These materials are highly reactive, requiring close and constant monitoring of reactors, oxidation units, distillation towers, and specialized storage tanks
Shell Norco — Norco, Louisiana
Shell’s Norco complex combines a full-scale refinery with a major chemical manufacturing operation. The refinery produces gasoline, diesel, jet fuel, and other transportation fuels, while the chemical facility manufactures olefins and other feedstocks used across the petrochemical industry. The site includes hydrotreaters, reformers, catalytic cracking units, alkylation systems, furnaces, and flare structures that support continuous, high-volume production.
Shell Polymers Monaca — Monaca, Pennsylvania
Opened in November 2022, Shell Polymers Monaca converts ethane into polyethylene resin using cracking furnaces, polymerization reactors, pelletizing systems, and large-scale storage facilities. Polyethylene production involves rapid temperature shifts, combustible gases, and continuous operational pressures that require constant oversight.
Shell Carson — Carson, California
Once a full refinery, Shell Carson now serves as a major terminal for storing and distributing gasoline, diesel, and other refined products across Southern California.
Recent Shell Refinery Accidents and Explosions
Shell plants and refineries have experienced their share of accidents in recent years, including chemical releases and serious fires that injured workers and placed nearby communities at risk.
Shell Polymers Monaca Chemical Release and Flaring Events
In June 2025, an accidental release of butadiene and benzene from an ethane cracking unit at Shell Polymers Monaca triggered a fire. Although no one was injured, the incident was the most serious in a string of flaring events and accidental chemical releases, raising concerns about safety at the facility. According to media reports, the facility experienced at least 26 malfunctions and two shutdowns in its first year of operation alone. The plant has also been cited for numerous permit violations since it began operating, exceeding pollution limits on multiple occasions.
Shell Deer Park Fire
In May 2023, a large fire broke out at Shell’s Deer Park chemical plant, sending up a plume of smoke that was visible from surrounding neighborhoods. The blaze, which originated with a leak on the plant’s olefins unit during routine maintenance operations, burned off and on for three days before being permanently extinguished. After several days of silence, Shell finally acknowledged that 15 workers had sought medical treatment following the fire, including a number who were represented by Our Houston Refinery Accident Lawyers.
Shell Convent Fire
On July 4, 2023, a fire erupted in a pump area at the Shell Convent refinery in Louisiana, leaving three contract workers with injuries ranging from moderate to serious. The fire was one of four that had occurred at the facility since 2016, including a transformer fire at a substation that shut off power to sections of the plant the previous September. Two fires broke out on the refinery’s H-Oil Unit in August 2016 and March 2017. Fortunately, no workers were hurt in the earlier incidents.
Common Causes of Shell Refinery Accidents and Explosions
Having successfully represented over 1,000 refinery workers in Texas, Louisiana, and across the United States, we’ve found that the vast majority of fires, explosions, and other accidents are entirely preventable and occur only because the refinery operator or owner chose to prioritize profits over safety.
- Improper Storage and Handling of Hazardous Materials: When toxic or volatile substances are transferred between units, loaded into tanks, or routed through pipelines, refinery crews must maintain tight control of temperature, pressure, and flow. Any deviation — a line left open, a valve misaligned, or incompatible materials introduced into the wrong system — can create conditions that could trigger a fire, toxic release, or explosion.
- Defective or Malfunctioning Equipment: A single mechanical failure — whether from corrosion, cracking, worn seals, or manufacturing defects — can allow dangerous chemicals or vapors to escape, potentially igniting a fire or explosion.
- Missed Inspections and Deferred Maintenance: When inspections are delayed or repairs are postponed, small issues can grow into serious hazards. Defective or poorly maintained equipment can corrode, leak, and rupture, setting in motion a chain of events that eventually leads to disaster.
- Improper Hot Work Procedures: Cutting, welding, grinding, or using spark-producing tools near hydrocarbons are among the most common causes of refinery accidents and explosions. Even trace amounts of vapor can ignite if hot work is performed without adequate isolation, gas testing, or fire watch procedures.
- Insufficient or Inconsistent Training: Safe refinery operations depend on experienced workers who understand the hazards associated with each process unit. When the company fails to properly train employees on alarms, lockout procedures, chemical reactions, or emergency shutdown steps, the risk of a catastrophic event rises exponentially.
- Breakdowns in Safety and Operational Culture: When shift turnover is rushed, instructions are unclear, or critical steps are overlooked during maintenance or startup, the potential for disaster only rises. Even small communication breakdowns can lead to workers entering hazardous areas, energizing equipment too early, or relying on incomplete information.
- Hazardous Premises: Slippery areas, unprotected openings, falling tools, and other preventable hazards can result in serious injuries even outside of a refinery’s process units. Site conditions become especially dangerous during emergency responses, shutdowns, and turnarounds.
Workers’ Rights After a Shell Refinery Accident
Most Shell employees and contractors assume that workers’ compensation will be there for them after a serious refinery accident. In reality, these benefits are intended only to cover medical treatment and a portion of lost income. For most families, this means the first workers’ comp check is drastically smaller than the paycheck they relied on. When an injury results in weeks or months of time away from work, the financial strain only grows worse by the day.
Workers’ compensation also does not cover pain and suffering, physical impairment, disfigurement, emotional trauma, or the long-term loss of earning capacity that often follows serious workplace injury, all of which could be recovered through legal action were it not for the legal shield provided by workers’ comp.
Unlike every other state in the country, Texas allows private employers — including refinery contractors — to opt out of the workers’ compensation system entirely. However, these companies also lose the legal shield afforded to those providing coverage. That means their employees can file personal injury lawsuits against the company for work-related injuries, while surviving family members of deceased workers have the right to pursue wrongful death lawsuits and survival claims when a loved one dies on the job. Employers who have opted out are also barred from using certain defenses that might otherwise allow them to avoid liability.
In Texas and many other states, injured workers and their families can also sue employers when injuries result from the company’s gross negligence, regardless of whether workers’ comp is available. They can also sue any third party whose negligence caused or contributed to their injuries, even if they are collecting benefits.
Who Can I Sue After a Shell Refinery Explosion or Accident?
In our experience, industrial accidents and explosions rarely involve a single company or a single point of failure. Modern refineries and chemical plants rely on layers of contractors, specialty crews, engineering firms, equipment manufacturers, inspection companies, and third-party service providers. Identifying every party responsible for a refinery explosion accident is the only way an injured worker can recover compensation for the many losses workers’ comp doesn’t cover.
Shell, as the Facility Operator
As the refinery operator, Shell bears direct responsibility for maintaining safe facilities, training workers, and enforcing safety rules. If its failure to do so rises to the level of gross negligence or is shown to be intentional, injured employees would be able to sue the company. Contract workers employed by a third-party could also sue if the company’s negligence contributed to their injuries, even if their direct employer carries workers’ comp.
Contractors and Subcontractors Working Inside the Facility
Most refineries depend heavily on contractors, and any mistake or oversight by one of these companies can lead to serious accidents or explosions. In such a scenario, injured workers could sue the contractor to recover their losses.
Manufacturers of Defective Equipment
If machinery or equipment fails due to a design flaw, manufacturing defect, or inadequate warnings, the manufacturer may be legally responsible for any resulting injuries.
Engineering, Design, and Inspection Firms
External firms often design process units, assess equipment integrity, inspect welds, evaluate corrosion, or certify that certain systems are fit for service. If their work contains errors or omissions, those mistakes can create unsafe conditions that eventually result in an accident, exposing these firms to potential legal action.
Other Third Parties on Site
Large industrial facilities frequently involve temporary staffing agencies, transportation companies, turnaround management firms, logistics providers, and service companies responsible for waste handling, cleaning, catalyst management, or tank operations. If one of these parties contributed to the conditions surrounding the accident, they may also be named in any resulting lawsuits.
What to Do After a Shell Refinery Accident
After any industrial disaster, a company like Shell will immediately bring in a team of attorneys and investigators with a single goal: save money by paying injured workers as little as possible or even nothing at all. They’ll do whatever is necessary to achieve their objective, even if that means shifting blame, downplaying their injuries, and “losing” critical evidence proving the company was at fault.
If you’re going to recover the maximum compensation possible for all your injuries and losses, beyond whatever small amount in workers’ comp benefits you might be receiving, you MUST act just as quickly to protect your legal rights.
Seek Immediate Medical Attention
Get evaluated by a doctor as soon as possible, even if the injury doesn’t seem severe at first. Many refinery-related injuries — especially inhalation exposures, burns, and internal trauma — develop or worsen over time. Heading to the ER or urgent care in the immediate aftermath protects both your health and any potential legal claim.
Write Down What You Remember
As soon as you are able, record everything you recall about the incident. Details about sounds, smells, alarms, equipment behavior, or where workers were positioned often fade quickly but can become important later. Even small details could prove critical down the road.
Preserve Your Clothing, Gear, and Tools
Do not clean, repair, or discard anything you were wearing or using when you were injured. PPE, uniforms, boots, and tools in your position can contain residue or show damage that becomes valuable evidence. Store these items in a safe place and in a clean plastic bag until they can be reviewed by your attorney.
Collect Names of Coworkers and Witnesses
If others witnessed what happened or were working nearby, make sure you have their names and contact information. Refinery schedules change frequently, and contractors may rotate off-site within days. Getting this information early can make a significant difference later in your case.
Avoid Giving Recorded Statements
Company investigators and insurance representatives may ask for a recorded statement soon after the accident. You are not required to provide one, and what you say can be misinterpreted or used out of context. It’s safer to wait until you’ve received independent legal advice from your own attorney.
Do Not Sign Any Documents or Accept Early Settlement Offers
Paperwork presented shortly after an accident will likely limit your rights and lock you into a low-ball settlement before you know the full extent of your injuries. In our experience, early offers almost never reflect long-term medical needs or the real financial losses associated with refinery injuries.
Follow Medical Advice and Keep All Records
Attend all appointments and follow the treatment plan recommended by your doctor. Keep copies of medical reports, work restrictions, prescriptions, and receipts. Consistent documentation shows the seriousness of your injuries and supports your claim for compensation, while any failure to adhere to your treatment plan could be used to undermine your credibility.
Limit Social Media Activity and Discussion of Your Injuries
Posts, photos, or comments made online can be taken out of context and used to challenge the validity of your injuries. Keeping a low profile helps protect your case from unnecessary scrutiny. You should also limit any discussion of your injuries to your spouse and your attorney.
Assume You Are Being Monitored
Workers injured in industrial accidents are often placed under some form of surveillance. Investigators may misinterpret normal daily activities to assert your injuries aren’t as serious as you claim or even that you weren’t injured at all.
Consult With an Experience Refinery Accident Attorney
The sooner you consult with an experienced refinery accident attorney—ideally one with a history of success against the biggest oil and petrochemical companies in the world—the sooner they can launch an investigation, ensure evidence is preserved before it’s lost or destroyed, and begin building a strong case on your behalf.
Undefeated Shell Refinery Accident Lawyers: Call 1-888-603-3636 for a Free Consult
Our Undefeated Refinery Explosion Lawyers have won Billions for our clients, and we’ve consistently recovered record-setting verdicts and settlements against the largest refinery and petrochemical plant operators in the world:
- #1 Largest Burn Injury Settlement in History
- $100 Million settlement for workers injured in a refinery explosion
- $75 Million Settlement for workers injured in refinery explosion
- $85 Million Settlement for injured refinery contractors
If you or a loved one were seriously injured, catastrophically burned, or tragically killed while working at a Shell chemical plant or refinery, we’ll take on the company, its insurer, and their teams of attorneys on your behalf, so you and your family can focus on healing and rebuilding your lives.
Call 1-888-603-3636, use the “chat” button on our homepage, or click here to send us a confidential email through our “Contact Us” form.
Your consultation is free, and you won’t owe us anything unless we win your case.